Annexure – I-Technical Specification
NATIONAL ALUMINIUM COMPANY LIMITED
BID DOCUMENT No. :OT/05/2012-13/WT/RITES-BBSR/NALCO BBSR/NALCO-ANGUL
TENDER DOCUMENT FORDESIGN, MANUFACTURE, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF WAGON TIPPLER AND CONVEYOR SYSTEM FOR M/S. NALCO AT ANGUL.
CONTENTS 1. GENERAL 2. INTENT OF SPECIFICATIONS 3. SPECIAL STIPULATIONS TO BIDDERS 4. SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY 5. GENERAL TECHNICAL REQUIREMENTS 6. ELECTRICAL 7. CIVIL 8. CONDITION OF CONTRACT FOR FIELD SERVICES 9. MISCELLANEOUS
(A GOVERNMENT OF INDIAENTERPRISE) PROJECT OFFICE ST BHAGWANTOWER, 1 FLOOR CUTTACK ROAD, BHUBANESWAR – 751006 1
INDEX
DESCRIPTION
SECTION
PAGE NO
1
GENERAL
1-5
2
INTENT OF SPECIFICATIONS
1-17
3
SPECIAL STIPULATIONS TO BIDDERS
1-11
4
1-64
5
SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY GENERAL TECHNICAL REQUIREMENTS
1-27
6
ELECTRICAL
1-97
7
CIVIL
1-21
8
CONDITIONS OF CONTRACT FOR FIELD SERVICES
1-23
9
MISCELLANEOUS
1-55
2
SECTION 1 1.0
GENERAL M/S. National Aluminium Company Ltd. (NALCO), Angul have undergone 2nd phase expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to 1200MW. Facility for Storage and Handling of about 90,000 t additional uncrushed Coal has been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and shall have uncrushed coal supply connectivity to old and new coal bunkers bu through respective Crusherhouse.
2.0
3.0
Basic Data Material to be handled Feed size Specific gravity of coal
-
Moisture (%) No of working days / yr No of working shift / day
-
Uncrushed coal (Grade E / F / G) (-) 300 mm 0.8 t/m3 for volume calculation 1.1 t/m3 for strength calculation 6% to 10% 330 3 shift of 8 hrs per day
DESCRIPTION OF EXISTING SYSTEM The salient features of existing coal handling facilities consist of following:
3.1
mm size is brought from coalfields in Bottom Discharge Captive Railway ROM Coal of (-) 300mm Wagons.
3.2
Coal from coalfield is received through a Merry Go-round Go round (MGR) system between the CHP and coalfield.
3.3
There are two (2) nos. of existing Track Hopper Buildings with underground undergrou RCC hopper.
3.4
Each TrackHopperBuilding has four (4) nos. of paddle feeders of travelling type at its bottom to scoop coal from the track hopper. Two paddle feeders are mounted on individual conveyor.
3.5
There are two (2) underground conveyors at bottom of each track hopper. Both conveyors are running parallel at the bottom of the track hopper–1. hopper 1. The parallel conveyor installed at the bottom of track hopper–2 hopper run in opposite direction.
3.6
There are two (2) Bunker Bays. The old BunkerBay meets the crushed coal requirement for Unit 1 – 6 whereas the new BunkerBay meets the crushed coal requirement for unit 7 to 10. Thus, there are two separate conveyor paths. Each path has two conveyor streams running in parallel.
Technical Specification:Sec-1 General
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3.7
Rated & designed capacity of each conveyor stream is 800 TPH & 960 TPH respectively.
3.8
Two parallel conveyors with moving tripper are installed on the top of each BunkerBay. One moving tripper is provided on each conveyor installed on the top of BunkerBay. Bun Moving trippers feed the crushed coal in desired bunkers as per requirement.
3.9
house is provided on conveyor path The CHP has two (2) Crusher Houses. The old Crusherhouse that is feeding crushed coal to Units 11 6. The new Crusherhouse house is provided on conveyor con path that is conveying crushed coal to Unit 7 to 10.
3.10
& associated equipment installed on parallel Each Crusher house has two (2) Crusher& conveyor series. Thus, each Crusherseries series has been provided with dedicated Crusher and associated equipment.
3.11
There are three uncrushed coal storage yards with stacker cum reclaimer machine (SCR) in present CHP. One SCR machine is provided on each storage yard.
3.12
Storage yard 1 & 2 receive uncrushed coal from track hopper 1 & 2. Storage yard 3 receives uncrushed coal oal from track hopper 2 only.
3.13
Scooped uncrushed coal from track hopper 1 is conveyed to old Crusher house and then to coal bunker bay of Units 1-6 1 6 through conveyor path that is conveying crushed coal to coal bunkers Bay of Units 1-6. 6. OR, Uncrushed coall is conveyed to storage yard 1 & 2. Preparation of coal Stock Pile is carried out by installed Stacker--cum-Reclaimer Reclaimer (SCR) machine. Uncrushed coal is reclaimed by SCR machine and conveyed to either of boiler bunkers through dedicated conveyor paths which is operating for these two boiler bunker bays. OR, It is conveyed to boiler bunker Bay of Units 7 to 10 through new Crusherhouse Crusher by conveyor path that is feeding crushed coal in boiler bunkers of Unit 7 & 8. SCR machine is positioned in by-pass mode whilee conveying coal from track hopper 1.
3.14
Scooped coal from track hopper 2 is conveyed to Crusher house and then to coal bunker bay of Units 7 to 10 through conveyor path that is conveying crushed coal to coal bunkers Bay of Units 7 to 10. OR, It is conveyed to boiler bunker Bay of Units 11 6 through conveyor path linked with track hopper 1. OR, It is conveyed to storage yard 3. Preparation of stockpile is made with the help of SCR machine. Coal from the Stock Pile is reclaimed by SCR machine and is fed on to yard conveyor. The yard conveyor discharges the coal on to the conveyor path linked with boiler bunker bay of Units 7 to 10.
Technical Specification:Sec-1 General
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OR, It is conveyed to the storage Yard 1&2 through the conveyor paths linked with track hopper 1. 4.0
Additions to existing system currently under development:
Presently an additional coal storage and handling system is being implemented under a separate contract to augment the coal handling system. The salient features of the new scheme are: 4.1
The terminal points for Additional Additional Coal Storage & Handling System of CHP in 2nd Phase Expansion commences from and consist of:
4.2
Modification and shifting of discharge end of existing belt conveyor BC-115 BC in Junction House JH-7 7 with a provision of two way chute and flap gate to feed uncrushed uncr coal received from Track Hopper No. 2 to either the existing conveyor BC-116 BC 116 or to new conveyor BC-118A BC under implementation.
4.3
Modification of existing Junction House JH-7 JH 7 to accommodate tail end of new conveyor BCBC 118A for receiving & conveying uncrushed uncrushed coal to the proposed Additional Coal Storage Yard.
4.4
Provision of new Junction House JH-7A JH 7A adjacent to existing Junction House JH-7 JH to accommodate discharge / head end of new belt conveyor BC-122 BC 122 from the proposed Additional Coal Storage Yard and extended ex tail end of conveyor BC-116 116 to receive uncrushed coal from new conveyor BC-122. BC
4.5
Extension of tail end of existing conveyor BC-116 BC 116 from existing Junction House JH-7 JH to new Junction House JH-7A 7A to receive reclaimed uncrushed coal from the Additional Coal Storage Yard through a new conveyor BC-122. BC 122. Uncrushed coal received on conveyor BC-116 BC will be conveyed to the new Crusher house through existing belt conveyor system for supplying the crushed coal to bunkers of unit 7-10. 7 Extension of tail end of existing e conveyor BC - 104 from existing Junction House JH-2 JH to new Junction House JH-13 13 to receive reclaimed uncrushed coal from the Additional Coal Storage Yard through a new conveyor BC-120 BC and BC-121.Uncrushed 121.Uncrushed coal received on the extended conveyor BC-104 04 shall be Conveyed to the old Crusherhouse house through the existing belt conveyor system for supplying crushed coal to the bunkers of unit # 1-6. 1 6.
4.6
4.7
For Receipt of uncrushed coal for the proposed Additional Coal Storage and Handling System, uncrushed coal conveyed con to JH-7 by existing conveyor BC-115 115 from Track Hopper No.2 can be diverted either to existing conveyor BC-116 BC 116 or to new conveyor BC-118A BC at Junction House JH-7. 7. The new conveyor BC-118A BC 118A will convey material to the proposed Additional Coal Storage Yard Yard through a new conveyor system under development. For this, the existing Junction House JH-7, JH 7, shall be modified to accommodate the tail end of new conveyor BC-118A. 118A. The discharge chute of the existing conveyor BC-115 BC 115 shall be replaced
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with new chute arrangement gement having a two way chute with a flap gate. Two-way Two chute with flap gate will divert the material discharged from conveyor BC - 115 either to existing conveyor BC-116 116 or to the new conveyor BC-118A BC 118A depending on position of the gate. The discharge pulley of existing conveyor BC-115 BC 115 will be relocated suitably to ensure the flow of uncrushed coal, either to conveyor BC-116 BC 116 or to the new conveyor BC-118A BC is smooth through the new flap gate and chute arrangement. The rated capacity of conveying conv system is 800 t/hr. 4.8
For storage of uncrushed coal in the Additional Coal Storage Yard under development, the coal received through conveyor BC-118A BC 118A will be conveyed to the Yard through conveyors BCBC 119 & BC-120 120 and new Junction Houses JH-10 JH & JH-11. 1. The conveyor BC-120 BC will be equipped with a Slew Stacker Machine. The Slew Stacker Machine will be capable of forming two identical stock piles of uncrushed coal on either side of its track. The length of each stock pile will be 275 m. The storage capacity capacity of each Stock Pile will be 45,000 t of uncrushed coal. The rated capacity of stacking system is 800 t/hr
4.9
For Reclaiming the uncrushed coal from Additional Coal Storage Yard, a Bucket Wheel Reclaimer will be provided. The Bucket Wheel Reclaimer will be installed on conveyor BC 120 such that its discharge is collected on the yard conveyor BC-120. BC 120. The BWR will be operating on the same track as that of the Slew Stacker Machine. Simultaneous operation of stacking and reclaiming is also proposed on the yard conveyor BC-120. 120. Uncrushed coal reclaimed on conveyor BC-120 BC 120 will be conveyed to new Junction House JH-12. JH The rated capacity of the reclaiming system shall be 800 t/hr.
4.10
120 will convey reclaimed material to new Junction House JH-12. JH Head/ Conveyor BC-120 discharge scharge end of conveyor BC-120 BC 120 will be provided with two way chute with flap gate arrangement. Depending on position of flap gate in the discharge chute, uncrushed coal reclaimed from the Additional Coal Storage Yard will be diverted either to conveyor BC-121 BC or to conveyor BC-122 122 at new Junction House JH-12. JH Conveyor BC-121 121 will transport the material to new JH-13 13 and transfer material to the tail end of existing and extended conveyor BC-104, 104, Conveyor BC-122 BC 122 will convey the material to new Junction House JH-7A J and transfer the material to tail end of existing and extended conveyor BC-116. BC The rated capacity of conveying system is 800 t/hr.
4.11
Conveying of uncrushed coal to new Crusherhouse.. Uncrushed coal received on conveyor BC-122 122 will be conveyed to new Junction House JH-7A, JH 7A, located adjacent to existing JH-7. JH At Junction House JH-7A, 7A, conveyor BC-122 BC 122 shall discharge the uncrushed coal at the extended tail end of existing conveyor BC-116. BC Uncrushed coal received on conveyor BC-116 BC will be conveyed to the new Crusherhouse Crusherhouse through the existing coal flow path. The rated capacity of conveying system is 800 t/hr.
4.12
For Conveying the uncrushed coal to the old Crusher house, uncrushed coal received on conveyor BC-121 121 shall be conveyed to new Junction House JH-13. JH 13. At this new Junction House JH-13, 13, conveyor BC-121 BC 121 will discharge the material to the extended tail end of the
Technical Specification:Sec-1 General
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existing conveyor BC-104. 104. Coal received on conveyor BC-104 BC 104 will be conveyed to the old Crusherhouse house through existing coal flow path. The tail end of existing conveyor BC-104 BC at JH-2 2 will be extended up to the new Junction House JH-13 13 and a new conveyor gallery between existing Junction House JH-2 JH and the new Junction House JH-13 13 will will be provided to house the extended length of existing conveyor BCBC 104. The system rated capacity is 800 t/hr. 4.13
Dust Suppression System will be provided at all transfer points at various Junction Houses and uncrushed coal storage yard.
4.14
on and air conditioning facilities will be provided in Switch gear cum MCC Suitable ventilation room, Battery room, Transformer rooms.
4.15
PLC based operation & control system is being provided for additional coal storage & handling system. Controls are being suitably interfaced with existing conveyor system through limit switches.
Technical Specification:Sec-1 General
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SECTION 2 1.0 1.1
INTENT OF SPECIFICATIONS This specification is intended to cover the following activities and services in respect of all the equipment of Wagon Tippler and Conveyor System Package to be installed for National Aluminium Company Limited (NALCO), Captive Power Project located in Angul Angu of Orissa State in India. (a.) The broad scope of work covers the following: i. Detailed design and engineering of all the equipment and equipment system(s). ii. Complete manufacture including shop testing/ type testing. iii. Providing engineering data, drawings, Commissioning procedures and O & M manuals, etc. for the Owner/RITES’s Owner ’s review, approval and records. iv. Packing and transportation from the manufacturer’s works to site. v. Receipt, unloading, storage, preservation and conservation of equipment at site. tion, pre-assembly, pre assembly, (if any), erection, testing and satisfactory operation vi. Fabrication, of all the equipment including successful completion of facilities. vii. All associated civil, structural,electrical structural and C&I works. viii. Commissioning and completion of facilities and Performance Guarantee Tests. ix. Furnishing of mandatory spares and handing over to NALCO stores. x. Supply of commissioning spares xi. Reconciliation (if any) with custom authorities. authorities xii. Satisfactory conclusion of the contract. (b.) The equipment and services to be furnished and installed as required in this Technical Specification shall also meet all the requirements as stated in other sections of bid documents which shall be considered as a part of this technical specification as bound herewith. (c.) The Contractor or shall be responsible for providing all materials, equipment and services, specified or otherwise (unless specifically excluded) which are required to fulfill the intent of ensuring operability and the reliability of the complete system covered under this specification. (d.) It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation.
(e.) Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and d quality desired. Other manufacturer’s products may also be considered Technical Specification Sec-2,:Intent :Intent of Specifications
Page 1 of 17
provided sufficient information is furnished so as to enable the Owner/consultant Owner to determine that the products are equivalent or superior to those named. to carefully examine and understand the specifications and seek (f.) Bidder is requested to clarifications, if required, to ensure that they have understood the specifications. Such clarifications should reach Owner/consultant Owner at least 15 days before the scheduled date of the opening of the bids. The Bidder’s offer should not carry any sections like clarifications, interpretations and/or assumptions. (g.) If the Bidder feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, those may be highlighted separately. The Bidder may also make alternative offers provided such offers are superior in his opinion. In which case, adequate technical information, operating feedback,, etc. shall be enclosed with the offer, to enable the Owner/cons /consultant to assess the superiority and reliability of the alternatives offered. In case of each alternative offer, its implications on the performance, guaranteed efficiency, auxiliary power consumption etc. shall be clearly brought out for the Owner/consultant to make an overall assessment. In any case, the base offer shall necessarily be in line with the bidding documents/ specifications. Under no circumstances the equipment / system specification in Technical Specification shall be brought out as alternative offer. (h.) Any deviation or variation from the scope, requirement and/or intent of this specification shall be clearly defined by the Bidder in “Deviation to NIT Document” irrespective of the fact that such deviations/ variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for those deviations/ variations covered under Deviation Schedules, which are accepted by the Owner before the award of the Contract, it will be the responsibility of the Bidder to fully meet the intent and the requirements of the specification within the quoted price. No other deviation whatsoever from this specification, except for the declared deviations deviations submitted by the Bidder with his proposal under “Deviations to NIT Document” Document” shall be considered. Bids not complying with this requirement shall be treated as non-responsive non responsive and hence liable for rejection. The interpretation of the Owner/consultant Owner in respect of the scope, details and services to be performed by the Bidder shall be binding unless specifically clarified otherwise by the Owner/RITES in writing before the Award of the Contract. and examine the site and its (i.) Before submitting his bid, the Bidder should inspect and surroundings and should satisfy himself as to the nature of the ground and subsoil, the quantities and nature of work, materials necessary for completion of the work and their availability, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the Owner. The contractor shall, prior to commencement of design work, carry out the Geo-technical technical investigation in the area proposed for development of wagon tippler and conveyor system package. The number of bore holes shall be decided by the contractor to ensure adequate data to carry out the design and guaranteeing the Technical Specification Sec-2,:Intent :Intent of Specifications
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installation. The cost of such Geo-technical Geo technical investigation is deemed to be included in the bid submitted by the contractor. (j.) The sizes of various buildings/conveyor galleries indicated in the tender drawings and the parameters of equipment indicated in various sections of technical specifications are the minimum requirements of the Owner. Any increase in these sizes or the parameters, if required to meet the system/maintenance/operational requirement shall be supplied supplie by the contractor without any extra cost implication to the Owner. (k.) The works under the scope of this contract are to be executed in an operating power station. The contractor shall take all necessary precautions to protect all the existing equipment, nt, structures, facilities and buildings etc. from damage. In case any damage occurs due to the activities of the contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be immediately made good by the contractor ntractor at his own cost to the satisfaction of the Owner. The contractor shall also take all necessary safety measures, at his own cost, to avoid any harm or injury to his workers and staff from the equipment and facilities of the power plant. (l.) Contractor should note that the existing rail lines within the plant area are operational with rail traffic of coal and liquid fuel rakes. Contractor shall take all precautions to ensure the safety of existing rail tracks and other associated facilities as well as the safety of his men, material and equipment from the operating rail traffic. The contractor shall plan and make all arrangements to ensure that disruption to the existing rail traffic is minimum and shall follow the instructions of the Owner in this regard. Further, contractor shall plan and coordinate all his activities considering restrictions, if any, on free access to his work areas due to the rail traffic. l of (m.) After award of work and, before finalising his layout especially the layout / levels conveyors, cable / pipe routes/transmission routes lines and other services, the contractor shall carry out a site survey to identify the location & details of existing facilities that may interfere with his proposed facilities. The contractor shall suitably suitably modify his layout / levels to prevent dislocation of existing facilities and any cost / time implication arising out of such modifications shall be to his account. Contractor shall also be responsible to determine and obtain the necessary details at site site as required for interfacing and interconnection with the existing system / facilities. (n) If during the execution of works it is found that there is interference with the existing facilities / structures, the contractor shall revise his design / detailed detailed drawings to clear the interference and shall provide all necessary measures for the safety of existing structures. No claim in terms of cost or relaxation in time shall be entertained for any redesign, rework and for safety measures provided. If at any any stage of work, any dismantling or modification or relocation of any existing facility is required to be done to complete the work in contractor’s scope and which has been agreed by the Owner, the same shall be done by the contractor at no extra cost or time time implication to the Owner. All such changes will be as per drawings and work plan approved by the Owner. Technical Specification Sec-2,:Intent :Intent of Specifications
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Equipment and services covered under WAGON TIPPLER AND CONVEYOR SYSTEM PACKAGE are described in the subsequent sections: 1.2
cifications of equipment / system indicated in various sections as above In addition to the specifications and General Technical Requirement and Erection Conditions of Contract attached of the Specification shall also form part of this Technical specification.
1.3
TENDER DRAWINGS
1.3.1
The drawings listed elsewhere, form part of the specification and shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this package shall be as identified in these drawings and read in conjunction co with the text of these specifications. These drawings are preliminary drawings for bidding purpose only and subject to changes that may be necessary during the detailed engineering. In case of any conflicts / contradiction among various volumes volumes / sections / annexures / chapters / appendices / tender drawings of bid documents, the same shall be referred to the Owner for clarifications whose decision shall be final and binding. No extra claims shall be allowed on this account.
1.3.2
2.0
IPTION OF PROJECT BRIEF DESCRIPTION NALCO intends to augment the coal handling facilities at its Captive Power Plant by an additional annual volume of 2.0 Million tonnes. For this purpose, it intends to install a wagon tippler and connecting conveyor System to receive the above quantum of coal through rail mode. The wagon tippler system shall be suitable for handling all prevailing wagons in coal circuits such as BOX / BOX-N BOX / BOXNHA / BOX N.MKDII. The facility provided shall be suitable to accommodate locomotives of maximum maxi 140 T weight passing through the platform at a maximum speed of 8kmph. The Wagon Tippler System shall have an in built weighing mechanism (load cell type) below the platform for weighment of wagons prior to and after each tippling cycle to record the exact quantity of coal unloaded from each wagon. Coal received at the tippler hopper would be transported by belt conveyors and integrated to existing system for feeding the existing and the new stockpiles under development.
2.1
BRIEF DESCRIPTION OF PROPOSED PROPOSED WAGON TIPPLER AND CONVEYOR PACKAGE (i) Indian Railway rakes consisting of Box-N Box N wagons shall transport coal to the power plant. These Box-N N wagons are proposed to be unloaded in underground RCC hopper by means of a Rota side Wagon Tippler/Rotary Tippler Wagon Tippler.. Wagon tippler hopper shall have a holding capacity of minimum 2 wagons loads of coal. coal One Rota side wagon tippler/Rotary tippler
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WagonTippler(WT-1) 1) is to be utilised for unloading of IR coal rake. A Side arm charger is envisaged for placement of loaded wagon on the tippler table & retrieval of empty wagon from the tippler table after tippling. Clear access shall be provided for movement of pay loaders on the hopper side of Wagon tippler. Wagon tippler hopper grating is to be positioned and designed d accordingly. (ii) Apron feeder is proposed under the Wagon tippler for extracting coal from the Wagon tippler hopper and feed into the apron feeder which in turn discharges crushed coal on to the proposed receiving conveyor RC-1. RC Conveyor RC-1 will transfer sfer the coal to conveyor RC-2 RC at the new transfer tower TP-1. TP Conveyor RC-2 2 shall feed coal on to existing Conveyor BCBC 103/BC-115 115 at the existing junction house (JH-1). (JH 1). The rated capacity of all the conveyors in this package shall be 1200 TPH. (iii) The existing CHP control and monitoring system is PLC based. It is proposed to provide an independent PLC based control for smooth, efficient & trouble free operations of Wagon Tippler and conveyor system package. The control and monitoring system for belt conveyors con covered under this Package shall be integrated with the existing control system such that the operation of existing CHP is not hampered. Necessary interlocks and software changes in the existing PLC logic are also envisaged in this package. 3.0
SCOPE OF WORK
3.1.1
The scope of Wagon Tippler and Conveyor System Package to be furnished, erected and commissioned under this specification shall be as detailed hereinafter. The Contractor shall be fully responsible for system and detailed design, engineering, engineering, manufacture, shop fabrication, assembly, testing and inspection at manufacturer’s works, packing, dispatch, transportation, transit insurance, custom clearance etc. as applicable, delivery to site, unloading, handling and storage at site, insurance during during storage, construction, erection, including erection supervision, testing, inspection, commissioning and handing over to Owner and Guarantee testing including all associated electrical, civil & structural works as specified, unless specifically excluded exclude as per Section-Terminal Terminal Points & Exclusions.
3.1.2
The scope of the contractor shall be deemed to include all such items which although are not specifically mentioned in the bid documents and/or in Contractor’s proposal but are needed to make the system complete in all respects for its safe, reliable, efficient and trouble free operation and the same shall be furnished and erected unless otherwise specifically excluded in this document. The general description of the proposed system and the broad scope off work under the specification shall include but not be limited to as detailed below.
3.1.3
An underground RCC Wagon Tippler Hopper, machinery hatches with wagon tippler hopper, associated underground tunnel, transfer point and pent house complete with civil, ci structural and electrical works for Wagon Tippler hopper and machinery hatches, steel grating over hopper portion, removable chequered plate covers over openings in machinery hatches for handling underground equipment, equipment handling facilities for for apron feederinside feeder
Technical Specification Sec-2,:Intent :Intent of Specifications
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below wagon tippler hopper including the structural steel shed with E.O.T crane over the WT-1 1 and other equipment/systems such as Dust Suppression system, ventilation system, drainage system etc. as specified elsewhere in the specification. specification. However, the track work is excluded from Contractor’s scope however rails over tippler table and the track for Side Arm Charger are included in Contractor’s scope. 3.1.4
One (1) no. Rotaside Wagon Tippler/Rotary Tippler Wagon Tippler complete with clamping arrangements, all structural members, tippler platform, tippling mechanism, tippler drive along with necessary controls, associated electricals, civil / structural works and accessories.
3.1.5
Side arm charger associated with the Wagon Tippler complete with travel rails, drive equipment along with necessary controls, associated electricals, civil/structural works & accessories.
3.1.6
One (1) no. Apron feeder complete with drives, all mechanical, electrical accessories & supportingg structure etc.
3.1.7
Receiving Belt Conveyors RC-1 RC 1 complete with conveyor supporting structures, short supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units, pulleys, idlers, gravity take ups, take up structure upto upto ground level, take-up take platforms at intermediate level, internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic electro hydraulic thruster brakes, all electricals etc. including RCC tunnel for receiving Conveyor RC-1 RC and nd underground tunnel portion upto pent house of Conveyor RC-1 1 with all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations.
3.1.8
A new pent house along with over ground structures, structures for conveyor Rc--1 complete with all civil structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, RCC/steel floors, external staircases, hand rails etc.
3.1.9
1 complete with civil, structural and electrical works and associated A transfer point TP-1 foundations for transfer of coal from conveyor RC-1 RC to conveyor RC-2.
3.1.10 Complete chute work along with chute plug switches and actuator operated flap gates in all Transfer points, nts, maintenance platforms along with suitable approach. 3.1.11 Adequate number of ventilation equipment for ventilating the wagon tippler hopper, underground conv. RC-1 1 upto Pent House, complete with all mechanical, electrical, civil and structural works. 3.1.12 Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with all mechanical, electrical, accessories, civil and structural works.
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3.1.13 Air conditioning of Wagon Tippler control room, room PLC room and battery room, room complete with all electrical, civil & structural works etc. 3.1.14 Exhaust fans for all toilets complete with electrical, civil & structural works etc. Exhaust fans along with required ducting shall also be provided for all underground structures/Transfer Points. 3.1.15 Minimum of four (4) Nos. sump pumps in Wagon Tippler house complete with motors, local control panel, level switches, individual discharge piping with fittings and valves to nearest plant drain etc. control of fugitive dust at Wagon tippler, apron 3.1.16 A complete dust suppression system for control feeder, transfer points, complete with enclosed pump houses, water tanks, pumps, drives, hoisting arrangements, piping, valves etc. electrical, accessories, civil and structural works as briefly specified below: a) Plain water dust suppression through fogging nozzles for control of dust during Wagon Tippler operation. b) Dry fog type dust suppression system at all Transfer Points both at discharge and loading points including all electrical and accessories. c) Compressor units, Pump houses & water tanks for dust suppression, service water and cooling water system. 3.1.17 Cooling water system for scoop coupling, Service water system for Wagon Tippler Package System shall be taken from nearest header located at new track hopper hopper area. 3.1.18 An E.O.T crane for installation & maintenance of equipment in wagon tippler complex complete with all electrical and control including the covered structural steel shed. as hand operated chain pulley blocks 3.1.19 Monorails and electrically operated hoist blocks as well as for servicing/installation/easy replacement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment. 3.1.20All All buildings in contractor’s scope shall be complete with all electrical, civil, civ structural, architectural works, cable trenches, fire safety walls, foundation / fencing / earthingfor earthing all equipments, structures, transformers etc.. All cables / duct banks, trenches, cable trestles shall be complete with associated civil/ structural work work and necessary civil foundations. 3.1.21 Drainage of Wagon Tippler hoppers, tunnels, conveyor galleries, TPs, upto nearest existing CHP drain including all civil & structural works. insert plates, bolts, accessories, MS 3.1.22 All equipment/fittings, supporting structure, along with insert sleeves, base plates, grouting as may be required and proper alignment etc. 3.1.23 A complete set of all special tools and tackles, which are necessary or convenient for erection, commissioning and overhauling of any equipment, covered under the scope.
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3.1.24 First fill of all consumables e.g.; oils and lubricants for one year toppings requirements. r 3.1.25 Preservative shop coating, final painting of all structures and equipment under the scope. unction houses, Wagon 3.1.26 (a) Adequate fire alarm & detection of coal conveyor gallery area, Junction tippler area, Electrical switch gear rooms, Control Control rooms, Battery rooms, Transformer rooms, cable spreader rooms etc. consisting of heat detectors(both detectors(both ceiling mounted & Canopy mounted type), smoke detectors, LHS cables, manual call points, fire alarm panels at main control room of Wagon Tippler, repeater repeater panel at CISF Fire control room near CPP main gate etc shall be considered. Fire alarm & detection de ction system shall be of Intelligent Addressable type of Notifire/Siemens make. (b) b) The successful bidder is to obtain necessary approval from TAC for the complete Fire protection System of Wagon Tippler Package. (c) c) Underground pipes will be M.S heavy duty with coating wrapping by 4mm thick coal tat tape conforming to IS15337 (latest version). Over ground pipes shall be of heavy he duty GI pipes with fittings etc. Suitable number of water actuated deluge valves shall be provided for the hydrant system. Hydrant line will be tapped suitably from the existing hydrant net work. d) The coal conveyors shall also be provided with MVW (Medium Velocity Water) Spray (d) System which h will be operating automatically for protection of conveyors. 3.2
Electrical System / Equipment
3.2.1
Unless specifically excluded, contractor’s scope of work shall include all electrical works wor as required for putting into successful operation of the Wagon Tipplers & Associated Conveyors covered under this specification.
3.2.2
LT SWITCHGEAR 415V Switchgear/motor control centers distribution boards, AC & DC fuse boards, local emergency stop push button stations for all drives and local motor starters as required for plant and equipment.
3.2.3
MOTORS Motors along with couplings and coupling guards for all rotating auxiliaries are covered under this package. All motors shall be with cable glands & lugs.
3.2.4
CABLES HT & LT Power cables, control cables, Instrumentation cables and any special cables required for connection between equipment / devices in Contractor’s scope and also cables between Owner’s equipment and Contractor's equipment.
3.2.5
CABLING, EARTHING AND LIGHTNING PROTECTION
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(a) All cabling with cable accessories, cable trays with supporting structure, terminations and jointing kits, trenches, overhead trestle, duct banks etc. as required for the cables to be supplied by the Contractor. (b) Grounding and lightning protection for the plant and equipment under Contractor’s scope along with its interconnection to the nearest Owner’s earth grid at two points. 3.2.6
ILLUMINATION SYSTEM Complete illumination system as required for complete internal and external lighting of associated plant, equipment and buildings covered under Contractor’s scope including 2 Nos. of Lighting Masts for area lighting in W.T. area.
3.2.7
CONTROL SYSTEM An independent Control desk, PLC panels, I/O I/O racks, UPS, battery & battery chargers etc. for the control of Wagon Tipplers and other equipment. One (1) No. control building to be located near WT-1 WT 1 . This building shall have two floors i.e. ground & first floors. The first floor of control room shall house PLC panels, control desks for operation of WT-1. 1. One office room (5m x 5m) at the first floor. There shall be a projected viewing balcony at a suitable location to have clear view of the Wagon Tipplers Tipp during operation. The ground floor shall house the MCC, DBS, Battery DBS etc.
3.3
CIVIL WORKS
3.3.1
The work to be performed under this specification consists of providing all labor, materials, construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractor’s supervision and in strict accordance with the drawings and specifications. The nature of work shall generally involve earthwork in excavation including very deep underground excavation, de-watering, de watering, shoring and strutting, sheet piling, back filling around completed structures and plinth protection, area paving, disposal of surplus excavated materials, aterials, piling, concreting including reinforcement and form work, brick work, fabrication and erection of structural / miscellaneous steel works, inserts, architectural items & finishes such as plastering, painting, flooring, doors, windows & ventilators,, glass and glazing, rolling shutters etc., permanently colour coated profiled steel sheeting,, Aluminum industrial troughed sheets, sheets anchor bolts, R. C. C. trenches with covers, drainage, damp proofing, water proofing and other ancillary items. Supply of cement, reinforcement steel, structural steel sections ,MS rounds, chequered plates, flats etc will be within the scope of the bidder. bidder
3.3.2
The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment equipment foundations, grounding, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer
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galleries, trestles, penthouses, Wagon tippler hopper, underground tunnels, transfer points, finishes, hes, complete architectural aspects, drainage and all other civil, architectural and structural works associated with the complete Wagon Tippler and conveyor system Package. 3.3.3
Scope of work shall also include dismantling and modifications of the existing exi structures/facilities, which may be required to facilitate, inter connection between the existing and the new structures or facilities and making good the dismantled/modified structures.
4.0
TERMINAL POINTS Terminal point for Wagon Tippler and conveyor system commences from wagon tippler complex upto feeding points at conveyors BC-103 BC & BC-115, 115, in Junction House (JH-1) (JH including the modification necessary to the Junction Houseand and interconnection with the existing system. Within these terminal points, all equipment and services, civil, structural and architectural works, electrical distribution, piping network etc. as required for wagon tippler and conveyor system package will be furnished and erected by the contractor co unless specifically excluded.
4.1
Contractor's Scope responsibilities shall include but not be limited to the following:
4.1.1
Wherever Contractor is permitted by Owner to take support from any of the Owner’s Structures, the Contractor shall ensure that no damage is done, to the Owner’s Structures including Painting thereof. In case of any damage to the Owners Structure and/or Painting, then the Contractor shall rectify the same to the complete satisfaction of the Owner.
4.1.2
JH 1 and shall ensure that the proposed The contractor shall carry out the redesign of JH-1 modifications are adequate to support the discharge point of the conveyor RC-2 RC as well.
4.1.3
Regarding erection of transfer point on existing junction house-1, house 1, contractor shall ensure ensur that opening on existing building and erection of conveyor chutes/skirts & platform are done in a manner to minimize shut down of existing conv. BC-103 BC & BC-115. 115. As work is to be executed in operating project, extra care must be taken by the Contractor.
4.1.4
Water supply connections for dust suppression, service water system & cooling water shall be provided by the Owner, details of which are given elsewhere in the specification. Further network of piping including all compressors, pumps, tanks, necessary necessary accessories, supports and fittings etc. for distribution of water for dust suppression and service water system in all transfer points, control rooms, MCC rooms, toilets, Machinery hatches of the Wagon tippler etc. shall be under the scope of the contractor. contra
4.1.5
Road lighting in wagon tippler area, for the roads, is included in the scope of Contractor.
4.2
EXCLUSIONS
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4.2.1
Supply, laying and fixing of rail track for the inhaul and out haul siding is excluded from fr the scope of this Contract. However, supply, laying and fixing of rail over Wagon Tippler table and for side arm charger is included in the scope of this Contract.The Contract.The approaches of wagon tippler where track is to be laid on concrete base( to the extent required) equired) and aligning with the inhaul/outhaul haul/outhaul track junctions is also included in the scope of this contract the cost of which is deemed to be included in the quoted rate of relevant items. items
5.0
SYSTEM DESIGN BASIS
5.1
The rated capacity of the Conveyors shall be 1200 TPH.. The design capacity of the conveyors shall be 1320 TPH.. The mechanical and structural / civil system shall be designed for 1320 TPH capacity and round the clock operation with both the streams operating operatin simultaneously.
5.2
Following shall be considered while designing the Conveyors : a. The Coal delivered to the power station shall be of size 300 mm & below. However occasionally coal of higher lump size may also be encountered. b. HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary between 6% to 10%. However for design purposes, moisture content of 10% shall be considered. c. The coal “as received” shall contain varying percentage of fines. Coal with such fines may tend to form orm adhesive lumps, particularly during monsoon when surface moisture is at its maximum value. d. The sizing and selection of the vital equipment viz. apron feeder covered under the system shall be based on the above characteristic of coal and operating conditions. conditions. Contractor shall ensure that equipment/ system efficiency shall not be effected particularly during monsoon when surface moisture is at its maximum value.
5.3
For the purpose of volumetric computation, the bulk density of the coal shall be taken as a 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. the above bulk density shall be considered. For all other purposes viz. for stresses/ load on structures, loading on Apron Feeder tables, sizing of actuators for flap gates, calculations of plugged chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3.
5.4
Coal Flow paths
5.4.1
For the purpose of conducting guarantee test coal, the following flow path would be assessed.
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Apron feeder will feed coal unloaded at WT-1 WT to Conveyor RC-1. 1. Coal on RC-1 RC will be transferred to RC-2 2 through Transfer point feeding on to existing Conveyors (either BC-103 BC or BC-115) in JH-1. 5.4.2
Contractor shall also demonstrate that all intermediate equipments can perform as per specification and design requirement during PG Test.
5.4.3
Performance and Guarantee tests have been elaborated elsewhere in the specification.
6.0
ENGINEERING NG SCHEDULES
6.1
Within one month of acceptance of Award Letter, Contractor shall submit, for review and approval, detailed engineering schedules, based on Master Network (as per requirement of bid documents), to the Owner / Consultant, showing the logic & duration of activities in the following areas : a) Detailed engineering, including submission and approval of quality plans and PG test procedure. b) Inputs required from Owner for smooth and timely execution of contract.
6.2
The Contractor shall submit within 30 days of letter of award a master list of drawings incorporating the scheduled dates of submissions. The schedule date of submissions should match with the manufacturing and erection programme submitted in the detailed Master Network Schedule. The list shall be updated every month reflecting the additions / deletions during the period.
6.3
The network schedule shall be updated at a frequency mutually agreed upon for the purposes of progress monitoring. However, for the purpose of identification of Contractor's Contractual Liability the agreed Master Network shall only be applicable.
7.0
GUARANTEE AND LIQUIDATED DAMAGES
7.1
Guarantee The Bidder shall guarantee that equipment offered shall meet the rating, performance and functional requirement stipulated stipulated for various equipment covered in this specification. The Bidder shall also furnish a declaration in the manner prescribed and included in the Bid Proposal Sheets and other Schedules for certain guaranteed parameters which shall attract levy of liquidated uidated damages for shortfall in performance.
7.2
Performance Requirement Guaranteed parameters of the major equipments shall be as follows:
7.2.1
Flow Path Capacity Flow path capacity including the intermediate equipment for conveyor streams to be tested teste for 1200 TPH
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7.2.2
Equipment Capacity Capacity of individual equipment shall be tested separately: (i) Each Wagon Tippler : 20 tips/hour (Guaranteed) (ii) Each Apron feeder : 1200 TPH (Guaranteed)
7.2.3
Contractor shall also demonstrate that all intermediate equipments viz. Gates, Dust suppression, Ventilation System etc. can perform as per specification and design requirement.
7.2.4
Performance and guarantee requirement of various other equipments have been elaborated elsewhere.
8.0
PERFORMANCE & GUARANTEE TEST PROCEDURE In accordance with GTR the plant shall be subjected to performance and Guarantee Tests on successful completion of trial operations. Further, the performance and Guarantee Tests shall be conducted as per the guideline procedure indicated elsewhere. However, detailed procedure shall be submitted by vendor as per the guidelines for Owner/RITES's Owner approval. The P&G Test procedure shall be submitted by the bidder.
8.1
Liquidated Damages for Shortfall in Performance Should the resultss of the performance and guarantee tests show that the equipments / system have failed to meet the guaranteed parameters, the Contractor shall carry out modifications, if considered necessary, within 90 days of the notification by Owner. If the equipment fails ails to meet the guarantee parameters at the end of the above specified period of 90 days, Owner may at his discretion, reject the equipment or accept it after assessing the liquidated damages at rates specified herein, to be payable by the Contractor.
8.2
The following equipments/streams shall be subjected to performance and guarantee test in line with the specification to prove the performance guarantee for all intermediate equipment. Liquidated Damages towards shortfall in guaranteed performance shall be imposed as % of the order value limiting to 5% against following parameters. Sl. No. 1
Equipment Wagon Tippler
Guaranteed parameter 20 Tips /Hour
2
Apron Feeder
1200TPH
3
Conveyors (R1 & R2)
1200TPH
Technical Specification Sec-2,:Intent :Intent of Specifications
Short fall By One tip per hour By two tips per Hour Beyond two tips per hour By 0.5% By 1.0% Beyond 1.0% By 0.5% By 1.0% Beyond 1.0%
LD amount to be imposed 1% of order value 2% of order value Rejected 1% of order value 1.5 of order value 1.5% Rejected 1% of order value 1’5 of order value 1’5% Rejected
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The LD shall be assessed on the basis of conveyor equipment having the poorest performance. 9.0
COMMISSIONING (SYSTEM TRIAL OPERATION) Duration of the trial operation of the he complete equipment shall be 30 continuous days with available no of loaded rakes during the period or as to be mutually agreed. agreed
10.0
TYPE TESTS AND TYPE TEST CHARGES
10.1
All equipment / systems to be supplied shall conform to type tests as per relevant re standards and proven type.
10.2
The Bidder / Contractor shall furnish the reports of all the type tests carried out within five years of the date of bid opening as per specification and relevant standards for all components / equipments / systems. These reports should be for the tests conducted on identical / similar components / equipments / systems to those offered / proposed to be supplied under this contract.
10.3
In case contractor is not able to submit report of type test(s) conducted in last five years, or in case type test report(s) are not found to be meeting the specification / relevant standard requirements, then all such tests shall be conducted under this contract by the Contractor free of cost to Owner, and reports shall be submitted for f approval.
10.4
All acceptance and routine tests as per relevant standard and specification shall be carried out. Charges for these shall be deemed to be included in the bid price.
11.0 11.1
SPARES GENERAL The Contractor shall include in his scope of supply all the necessary Mandatory spares, start up and commissioning spares and recommended spares and indicates these in the relevant schedules of the Bid Form and Price Schedules. The general requirements pertaining to the supply of these spares have been b described in the following paras.
11.2
MANDATORY SPARES
Owner/RITES is included in this 11.2.1 The list of mandatory spares considered essential by the Owner/RITES specification. The Bidder shall indicate the prices for each and every item (except for items not applicable to the Bidders design) in the the ‘Schedule of mandatory Spares . If the Bidder fails to comply with the above or fails to quote the price of any spare item, the cost of such spares shall be deemed to be included in the bid price unless the bidder specifies "not applicable" for the type of equipment/system offered by him. him. However during execution if such spares are found to be applicable, the Contractor shall supply them without extra cost to the Owner. The Bidder shall furnish the population per unit of each item in the relevant Technical Specification Sec-2,:Intent :Intent of Specifications
Page 14 of 17
Schedules. Whenever the quantity is mentioned mentioned in “sets” the Bidder has to give the item details and prices of each item. 11.2.2 Whenever the quantity is indicated as a percentage, it shall mean percentage of total population of that item in the Package, unless specified otherwise, and the fraction will be rounded off to the next higher whole number. Wherever the requirement has been specified as a ‘set’ it will include the total requirement of the item for a unit, module or the station or as specified. Where it is not specified a ‘set’ it will include the the total requirement of the item for a unit, module or the station or as specified. Where it is not specified a ‘set’ would mean the requirement for the single equipment/system as the case may be. Also one set for the particular equipment. e.g. ‘set’ of bearings bearings for a pump would include the total number of bearings in a pump. Also the ‘set’ would include all components required to replace the item; for example, a set of bearings shall include all hardware normally required while replacing the bearings. 11.2.3 The Owner reserves the right to buy any or all the mandatory spare parts. 11.2.4 The prices of mandatory spares indicated by the Bidder in the Price Schedules shall be used for bid evaluation purposes. 11.2.5 All mandatory spares shall be delivered at site at least two months months before scheduled date of initial operation. However, spares shall not be dispatched before dispatch of corresponding main equipments. 11.2.6 Wherever quantity is specified both as a percentage and a value, the Contractor has to supply the higher quantity until u and unless specified otherwise. 12.0
RECOMMENDED SPARES
12.1
In addition to the spare parts mentioned above, the contractor shall also provide a list of recommended spares for 1 year of normal operation of the plant and indicate the list and total prices in relevant schedule of the Bid Form and Price Schedules. This list shall take into consideration the mandatory spares specified in this Volume, and should be independent of the list of the mandatory spares. The Owner reserves the right to buy any or all of the recommended spares. The recommended spares shall be delivered at project site at least two months before the scheduled date of initial operation. However, the spares shall not be dispatched before the dispatch of the main equipment.
12.2
Price of recommended spares will not be used for evaluation of the bids. The price of these spares will remain valid upto 6 months after placement of Notification of Award for the main equipment during which the Contractor shall provide necessary justification for the quoted prices for these spares. However, if the Contractor fails to provide the aforesaid justification of the quoted prices, the prices of recommended spare shall remain valid for 2 months from the last date of providing such justification to the satisfaction satisfaction of the Owner.
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13.0
START-UP UP & COMMISSIONING SPARES up and commissioning spares are those spares which may be required during the startstart Start-up up and commissioning of the equipment/system. All spares used till the plant is handed over to the Owner shall come under this category. The Contractor shall provide for an adequate stock of such start up and commissioning spares to be brought by him to the site for the plant erection and commissioning. They must be available at site before the equipments are energized. The unused spares, if any, should be removed from there only after the issue of Taking Over certificate. All start up spares which remain unused at the time shall remain the property of the Purchaser. Purchase
14.0 14.1
COMMON REQUIREMENTS The Contractor shall include in his scope of supply all the necessary Mandatory Man spares, start up and commissioning spares and recommended spares and indicate these in the relevant schedules of the Bid Form and Price Schedules. The general requirements pertaining to the supply of these spares is given below.
14.2
The Contractor shall indicate the service expectancy period for the spares parts (both mandatory and recommended) under normal operating conditions before replacement is necessary.
14.3
All spares supplied under this contract shall be strictly inter changeable with the parts for which they are intended for replacements. The spares shall be treated and packed for long storage under the climatic conditions prevailing at the site e.g. small items shall be packed in sealed transparent plastic with desecrator packs as necessary. necess
14.4
All the spares (both recommended and mandatory) shall be manufactured along with the main equipment components as a continuous operation as per same specification and quality plan.
14.5
The contractor will provide Owner with cross-sectional cross drawings, wings, catalogues, assembly drawings and other relevant documents so as to enable the Owner to identify and finalise order for recommended spares.
14.6
Each spare part shall be clearly marked or labeled on the outside of the packing with its description. When more than one spares part is packed in a single case, a general description of the content shall be shown on the outside of such case and a detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purposes urposes of identification.
14.7
All cases, containers or other packages are to be opened for such examination as may be considered necessary by the Owner.
14.8
The contractor will provide the Owner with all the addresses and particulars of his sub suppliers ers while placing the order on vendors for items/components/equipments covered
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under the contract and will further ensure with his vendors that the Owner, if so desires, will have the right to place order for spares directly on them on mutually agreed terms term based on offers of such Contractors. 14.9
The Contractor shall warrant that all spares supplied will be new and in accordance with the contract Documents and will be free from defects in design, material and workmanship.
recommended spares listed by the contractor, if the Owner further 14.10 In addition to the recommended identifies certain particular items of spares, the contractor shall submit the prices and delivery quotation for such spares within 30 days of receipt of such request with a validity period of 6 months onths for consideration by the Owner and placement of order for additional spares if the Owner so desires. 14.11 The Contractor shall guarantee the long term availability of spares to the Owner for the full life of the equipment covered under the contract. The Contractor shall guarantee that before going out of production of spares parts of the equipment covered under unde the Contract, he shall give the Owner at least 2 years advance notice so that the latter may order his bulk requirement of spares, if he so desires. The same provision will also be applicable to sub-contractors. contractors. Further, in case of discontinuance of manufacture manufacture of any spares by the Contractor and/or his sub contractors, Contractor will provide the Owner, two years in advance, with full manufacturing drawings, material specifications and technical information including information on alternative equivalent makes required by the Owner for the purpose of manufacture/procurement of such items. 14.12 In case of equipment supplied with grease/lubricants from imported origin, the supplier shall clearly indicate the indigenous equivalent of the grease/lubricant and and source of supply so as to enable the Owner to procure these items from indigenous sources.
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SECTION 3 (SPECIAL STIPULATIONS TO BIDDERS) 1.1.
GENERAL
1.1.1
This Technical Specification shall be read in conjunction with Commercial, General Condition of Contract and other project requirement mentioned in this specification.
1.1.2
The Bidder shall quote for complete scope of work as covered in this specification.
1.1.3
This Technical Specification is for turnkey supply of the plant & equipment and related structures including execution of structural steel works and civil works as specified in subsequent chapters, along with necessary modification, as detailed in the Scope of Work and Technical Specification.
1.1.4
idders / Special Instruction specified in other chapters shall be read in Instructions to Bidders conjunction with stipulation stated in this chapter.
1.1.5
The Bidder shall submit the drawings / documents, technical data / information as mentioned in various sections and annexure without which the Bid shall be considered as incomplete and may not be considered further.
1.1.6
The Bidder shall submit along with the bid a work schedule in the form of a bar chart indicating the commencement and completion dates of each activity activity such as preparation of design, approval of design & drawings, preparation & approval of fabrication drawings, procurement of steel and other material, ordering of bought out items, their delivery to shop, major shop activities like fabrication of structures/ structures/ manufacture of equipment, assembly, shop testing, inspection, shop painting &dispatch & to the site, schedule of erection, final painting after erection at site, testing and commissioning of Plant and Equipment, without which the bid may not be considered. consi
1.1.7
The Bidder shall clearly indicate the clause wise compliance to the specification. Non compliance with this and generalized statements like. "The equipment shall be manufactured as per IS standard / our specification etc" may result in rejection reje of the Bid. The deviation, if any, shall be clearly specified clause-wise clause wise in the format enclosed with this technical specification. In absence of deviation indicated, it will be presumed that the Bidder has no deviations.
1.1.8
er document and drawings shall be duly signed by the Bidder as a One copy of the Tender token of acceptance of all clauses / parameters / data mentioned therein and returned along with the Bid without which the Bid is liable to be rejected. In case the Bidder intends to change any ny data / parameter given in Technical Specifications the same shall be clearly mentioned in the deviation list, with reasons thereof.
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1.1.9
If the Bidder feels that any information/ data described in the technical specification needs to be modified, he shall indicate the same specifically and submit an alternative proposal, on the basis of the design data, that he considers suitable and capable of meeting the requirement of this specification.
shall be new and the best of their kind and 1.1.10 All the materials used and equipment supplied shall shall comply with the statutory requirements of the Govt. of Orissa, Govt. of India and the latest revision of the Indian Standards/ Indian Electricity Rules. Where the equipment/ material supplied is not according to to Indian Standards or regulations to which the equipment / material conform, the Bidder shall submit relevant document along with the Bid. 1.1.11 The Bidder shall visit the plant / site, and satisfy himself fully about the existing plant /site conditionss etc. The successful Bidder shall bear full responsibility for inferences and conclusions as to the nature and conditions under which the work is to be executed, including effect of climate, rainfall etc. Failure to do so shall not absolve the Bidder of his h responsibilities about the proper execution of the job. No claim for extra payments due to any special site conditions and ignorance about the site conditions shall be considered after acceptance of his Bid. For the site visit, the Bidder shall contact the Purchaser and take prior appointment from them. 1.1.12 The drawings of the existing coal handling plant, available with the Purchaser, can be made available to the successful Bidder for reference. However, for the areas of the plant for which drawingss are not available, the Bidder shall make site measurements and work accordingly. 1.1.13 The Bidder as far as practicable ensure that major equipments are brought to site in pre assembled condition to minimize site work and to achieve an early commissioning commissi of the equipment after delivery. Site welding shall be avoided as far as possible. The Successful Bidder before proceeding with design details shall satisfy himself about the site condition so as to avoid any difficulty in erection arising out of design. des 1.1.14 The equipment shall be inspected during different stages of its manufacture (starting from raw material till the completion of manufacture) by the Purchaser / his authorized representative at the Bidder's or his sub Successful Bidder's works as per the inspection procedure mutually agreed between the Purchaser or his authorized representative and the successful Bidder. Inspection shall be regarded as a check up and shall be in no way binding on the Purchaser. However, general terms and conditions conditions of inspection and testing is indicated in the subsequent chapter of this specification. 1.1.15 Documents of all electrical and mechanical equipment supplied with equipment shall be put up for inspection along with the equipment. After inspection, an an endorsement would be made in the inspection certificate about the availability of the documents.
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1.1.16 The offer shall be complete in all respects and any additional equipment, accessories, auxiliaries, services, work etc. which are not specifically mentioned in the specification but are required for smooth and trouble free operation and to achieve performance required to be guaranteed in terms of the Bid Document, shall be included by the Bidder in the offer. 1.1.17 The make of all bought out items shall be as per” List of preferred makes” of supplies and equipment mentioned in tender document. 1.1.18 Metric systems & English language shall only be used throughout the Bid and in the drawings. 1.1.19 The Bidder shall satisfy himself about his ability for completing the work as per the time schedule before submitting his offer. In case the Bidder is unable to adhere to the schedule indicated in this specification, the Bidder need not submit their offer against this Bid. Bid 1.1.20 A complete list of exclusions from Bidder's scope of work shall be clearly indicated in the Bid. 1.1.21 In case of any contradiction between Instructions to Bidder and Technical Specifications, stipulation in the Technical Specification shall prevail. 1.1.22 The Bidder has to carry out the work is such a manner that it does not affect the plant operations. If other Contractors are also engaged at the same work site for other jobs, the Bidder shall work in co-ordination ordination with them such that the the work of other Contractor is not affected. For integration of new facilities & the existing one, shutdowns period in phases, as per the schedule mutually agreed between “Purchaser” and successful Bidder would be provided. Hence, Bidder shall indicate in their offer, the stages at which the shut downs are required and their respective duration. 1.1.23 All parts of equipment requiring replacement or inspection or lubrication shall be so arranged/ assembled that they are easily accessible without the need of dismantling of other equipment or structures. All electrical cables shall be so laid that they are not liable to be damaged and can be easily inspected and maintained and when necessary any damaged cable can be accessed & replaced individually. 1.1.24 All equipment shall be complete with adequate safety devices wherever a potential hazard to personnel exists. Provision for safe access of personnel working to and around equipment for operation and maintenance, shall be provided. 1.1.25 The Bidder shall train the Purchaser’s personnel in all disciplines of the operation & maintenance of the plant & equipment being provided by them under the contract. maximu possible 1.1.26 Standardization of components and assemblies shall be carried out to the maximum extent to ensure interchangeability/as well as to minimize inventory levels.
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1.1.27 Bidders shall furnish drive ratings of all equipments including conveyors along with the offer. Conveyor profiles enclosed with this specification are indicative indicat only. 1.1.28 The Bidder shall include in his scope of supply, a complete set of new and unused special tools and tackles required for operation and maintenance of the plant and equipment. The list of tools & tackles considered in the bid shall also be submitted. 1.1.29 The Bidder shall include in his scope, the requirement of initial fill of oils, lubricants, grease, and all other consumables required for startstart up, testing, commissioning and performance guarantee uarantee tests of the unit/equipment. A list of such consumables shall also be furnished by the successful Bidder for Purchaser’s use. 1.1.30 The Bidder shall include in his scope the supply of spares required for successful commissioning of plant & equipment. equipment. The list of commissioning spares considered in the bid shall also be furnished along with the bid. 1.1.31 The Bidder shall quote separately for the spares required for the normal operation and maintenance of the plant and equipment for a period of 24 months to be reckoned from the date of taking over of the plant and equipment. A list of the spare parts shall also be furnished along with item wise price. subcont 1.1.32 The successful Bidder shall not offload the contract or part thereof to any subcontractor without written permission of the purchaser. In the event of subletting of any part of the work with due permission by the purchaser, the fact that such permission has been accorded shall not absolve the successful Bidder from any of his obligations and liabilities under the contract. 1.1.33 Subject to availability and at the request of the successful Bidder, water for construction purpose will be made available by the Purchaser at one mutually agreed point at site. The successful Bidder shall make make his own arrangement for any further distribution at his own cost. Water supply shall be free of cost and shall be provided as specified under clause no. 54.13 b) of the GCC. 1.1.34 Power Supply Subject to availability and at the request of the successful successful Bidder, Electric Power will be made available at one point only at a distance not more than 500 meters away from the Contractor’s premises. The power will be supplied at 400/440 Volt and shall be metered and charged at the rate as specified in the GCC. GCC. The successful Bidder should have sufficient number & capacity of DG sets to meet the emergency power requirements in the event of failure in power supply. 1.1.35 Civil and structural steel works
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The supply of conveyor galleries, trestles, Junction towers, towers, buildings & civil work are in the scope of this tender including the Design of Civil & Structural works , shall be within the scope of successful bidder. 1.1.36 Fire hydrant system The Bidder shall include in his scope the extension & rerouting of fire hydrant system to the wagon tippler & conveyor system. The hydrant line should be laid as per IS specification. 1.1.37
Exclusions:: Following items are excluded from the scope of work 1. Railway track system.
1.2
ERECTION
1.2.1
The successfull Bidder shall be responsible and perform the following with respect to the erection of the Plant and supplies.
1.2.2
The scope of work of the successful Bidder shall be complete erection of the Plant and Equipment etc. as specified in the Technical Specification. Specification. The Bidder shall make all arrangements to deliver the equipment at their site stores by wagons / truck / trailers, build his own stores (covered, uncovered and air-conditioned, air conditioned, if necessary) for the proper storage of equipment, maintain the stores stores and all related documents and records, transport the equipment to site for erection purpose and take an ErectionErection cum- Storage insurance policy covering all the risks including third party liability for all supplies as well as human life. All security arrangements also shall be made by the successful Bidder. Space only for stores and site office shall be made available to the Bidder by the Purchaser.
1.2.3
The successful Bidder shall take the equipment from their site stores and transport the same to erection site.
1.2.4
The successful Bidder shall unpack and do visual checking against physical damages to the equipment / cases, cleaning of equipment before start of erection. Damage / shortage if any, will be reported to the Purchaser / consultant and shall be rectified / replaced expeditiously, free of charge to Purchaser so as not to upset the erection and commissioning schedule. Delay on account of settlement of insurance claims by the successful Bidder shall not be considered an excuse for delay in completion. The successful Bidder shall lay and maintain properly all the temporary supply lines in the erection site for temporary power and water required for storage and erection purposes from a single point to be provided by the Purchaser. Drinking water shall also be made available at one central point at site. The successful Bidder shall make his own arrangement for any further distribution.
1.2.5
1.2.6
The successful Bidder shall arrange all necessary construction construction machinery/ equipment, tools & tackles, instruments, compressors, small hand tools, welding equipment, all commissioning instruments, erection & service bolts, nuts, jigs and fixtures, winches,
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alignment tools, precision levels etc., Crane/ hoists and other other equipment which may be required for carrying out the erection work efficiently within the time schedule provided herein the specification. Unless otherwise specified, the above construction materials shall be the property of the successful Bidder. However However Purchaser's prior permission shall be required for removal of these construction materials from the site. Successful Bidder shall ensure that proper documentation is maintained for such items, which are required to be carried back by successful Bidder after the completion of work. 1.2.7
The successful Bidder shall provide all temporary ladders, scaffolding materials, platforms, supports and other necessary facilities required for handling, erection, testing and visual inspection of supplies at the point point of installation and shall also provide necessary packing plates, wedges, shims, levelling screws etc. required for erection of equipment and technological structures.
1.2.8
The successful Bidder shall provide erection consumables like oxygen and acetylene gas, welding rods, solder lugs, oil, grease, kerosene, cotton waste, etc. required for erection of equipment and technological structures.
1.2.9
The successful Bidder shall shall erect and maintain his own site offices, main stores and site temporary stores as required for the work and arrange for maintaining in neat manner of the area placed at the Successful Bidder's disposal.
sufficient fencing, notice boards and lights to protect and 1.2.10 The successful Bidder shall provide sufficient warn others as may be considered necessary by the purchaser / consultant. All materials used for providing these facilities shall be properties of the successful Bidder. echnological structures will be erected as per the instructions of the 1.2.11 The equipment and technological suppliers & under the supervision of the supervisory staffs to be deployed by the successful Bidder at site and only with the approval of Purchaser / Consultant. The successful Bidder shall use pre-assembly assembly and mechanisation to the maximum extent in order to fulfill erection & construction targets. 1.2.12 The Successful Bidder shall align, level, couple and securely fix all equipment, appurtenances and accessories in accordance with drawings drawings and / or instructions of Purchaser/ Consultant. 1.2.13 Laying and termination of cables, bus bars, bus ducts, lightening protection and earthing shall be done by the Successful Bidder. 1.2.14 The successful Bidder shall be responsible for protection protection and / or diversion of all existing underground and over ground services, wherever required. The terms and conditions for protection / diversion of services not shown on drawing / indicated in the specifications shall be mutually agreed.
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1.2.15 Installation stallation and connection of all piping and fittings within the scope of work shall be responsibility of the successful Bidder. 1.2.16 The successful Bidder shall be responsible for checking the correctness of erection of mechanical equipment, technological technological structures and auxiliary systems, electrical equipment etc. as per the specification. 1.2.17 The successful bidder has to carry out the work in such a manner that it does not affect the operation of other plant/ shop. If other Contractors are also engaged engaged in the same work site for other jobs the bidder shall work with them in a co-ordinated co ordinated manner. 1.2.18 The successful Bidder shall be responsible for the management of erection work with proper and adequate supervision for ensuring progress of erection erection work and quality of workmanship. 1.2.19 The successful Bidder shall deploy required number of supervisory, skilled, unskilled and auxiliary labour as required for the erection work: as per detail mobilisation schedule (to be furnished with Bid by successful Bidder) and comply with such reasonable reasonabl instructions of the Purchaser / Consultant in the interest of satisfactory progress and completion of the work according to the schedule. The successful Bidder shall work in 3 shifts per day basis for meeting the completion target, if required within the contract price. 1.2.20 The successful Bidder shall organise the work in a manner that other work at site is not impeded and the workmen therein not endangered and shall arrange temporary access at site, if required for the erection work. essful Bidder shall return to the Purchaser all crates, packing cases and packing 1.2.21 Successful materials excess commissioning spares, oil and lubricants at a place designated by the Purchaser. during erection. 1.2.22 The successful Bidder shall conduct all necessary tests / checks during 1.2.23 The successful Bidder shall attend to the rectification of erection defects, if any, expeditiously. The successful Bidder shall arrange all testing instruments for such testing at site. 1.2.24 The successful Bidder shall carry out final painting of the Plant & Equipment and technological Structures etc. erected as per the instructions stipulated in the Technical Specification. 1.2.25 The successful Bidder shall be responsible for total commissioning of the Plant and equipment including cold trial run and demonstration of Performance Guarantee Test. The Purchaser's supervisory and skilled operating personnel shall, however, be available to work under the guidance and supervision of the Bidder. Necessary raw materials, auxiliaries, auxiliari
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utilities, electricity and operating personnel shall be made available by the Purchaser covering 3 shifts operation as per the programme agreed to in advance. reliabl and 1.2.26 The Successful Bidder shall supervise running of the Plant for satisfactory, reliable regular operation and performance after its successful commissioning for establishing performance guarantees. 1.2.27 Electrical energy and construction water shall be supplied by Purchaser to the successful Bidder during erection, at one point. 1.2.28 All safety measures required to be adopted as per the Statutory Regulations & the Safety Rules of the Plant shall be strictly followed by the successful Bidder during the execution of the Contract. The successful Bidder shall depute safety engineers engineers for strictly compliance of safety rules & regulations. 1.2.29 The successful Bidder shall intimate the Plant authorities in writing well in advance about the requirement of shut down of any of the existing units / facilities for inter connection / incorporation orporation of additional facilities. The shut down period shall be mutually discussed and finalised. The work to be undertaken during the shutdown period shall be planned meticulously to reduce the shut down period to the minimum. 1.2.30 The successful Bidder shall comply with all statutory Rules, Regulations with respect to the employment of labour at site. 1.2.31 The successful Bidder shall carry out any and all such works, as may be required, to build a Plant complete in all respect as per the Technical Specification and achieve the Performance Guarantees and other parameters as given in the subsequent chapter of this specification. 1.2.32 Any loss of plant and equipment due to imprudence, negligence and / or inequitable treatment and handling shall be replaced by the Successful Bidder / his sub-contractor sub at his own cost.
1.3
PAINTING All parts of the equipment ipment shall be thoroughly cleaned of loose mill scales, rust or foreign matters. All parts excepting motors, resistors, gears etc. shall be painted at shop and at site with two coats of epoxy zinc based on zinc dust. Interior of all gear housing shall be painted with oil resistant paint. All machine pads, bearings surface or structures or housing shall be painted with white lead. All parts, inaccessible after assembly, shall be painted and assembled while the paint is wet.
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After erection, the damaged portion of the painted surface shall be retouched and an intermediate coat / final coat of PVC copolymer alkyd resin with micaceaus iron oxide (MIO) shall be applied. The colour shall be as per the choice of the Purchaser. The subsequent one final coat of paint of PVC copolymer alkyd with weather resistant pigment (approved by the Purchaser) and glossy finish shall be applied. The details of the dry film thickness (DFT) of the different coats shall be as follows: a) b) c)
Primary coat Intermediate coat Final coat
: : :
30 –40 micron per coat 70 –80 micron per coat 40 –50 micron per coat
The painting scheme & colour code shall be approved by the Purchaser. The successful Bidder shall refer to Section 8 for further detail off painting scheme & colour codes. 1.4
OPERATING / PERFORMANCE PARAMETERS All the equipment covered in this specification shall fulfill the operating and performance requirement covered under this Technical Specification and indicated in the approved drawings. The successful Bidder shall study the specification and satisfy himself thoroughly regarding the workability and suitability of the equipment offered by him. He shall take full responsibility for the guaranteed and satisfactory operation of the equipment equipment as regards to its performance and smooth and reliable working.
1.5
PRELIMINARY ACCEPTANCE
1.6
After completing the erection of a unit or agreed portion thereof, the successful Bidder shall give a notice in writing stating that the job is complete in all respects and ready for preliminary acceptance. The job shall be visually inspected by representatives representa of the Successful Bidder and Purchaser / Consultant to ascertain whether supply, fabrication and erection are as per contract drawings and Technical Specification. All observed defects, deficiencies and omissions shall be noted down. If the defects, deficiencies and omissions are not major in the opinion of the Purchaser / Consultant, the successful Bidder shall be issued a preliminary acceptance certificate mentioning the defects, deficiencies and omissions. The noted defects, deficiencies and omissions omissions shall be made good by the successful Bidder within a period of 3 to 4 weeks. FINAL ACCEPTANCE Before commencement of final acceptance test of the building or unit, the successful Bidder shall make available required numbers of complete sets of ordinary prints of drawings, required numbers of set of DOD list for the drawings and one set of reproducible film of all
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drawings, all representing As-Built As Built condition (i.e. all additions and alterations done during fabrication and erection shall be incorporated incorp in the drawings). The successful Bidder shall attend to all defects, deficiencies and omissions noted down during preliminary acceptance and after rectifying or making good the above in all respects, shall inform 10 days in advance the Purchaser / Consultant for conducting final acceptance. During Final Acceptance all defects, deficiencies and omissions noted earlier shall be checked. The successful Bidder shall also make good any defect, deficiency or omission not notified during earlier preliminary preliminary acceptance, but pointed out during final acceptance. Final Acceptance certificate shall be issued by the Purchaser after all defects, deficiencies and omissions noted under preliminary or final acceptance have been rectified. 1.7
SCOPE OF WORK
1.7.1
The broad turnkey scope of work shall be as per the following: •
Design, manufacture, inspection, shop & primary coat of paint & supply of complete plant & equipment, fabrication (shop & site) of building structures & technological structures, civil construction materials, power distribution, electrics, instrumentation & automation, illumination, all utilities & services, in-plant in plant road networks, drainage systems, landscaping, fire detection & alarm system, fire fighting pump house, as required, for complete mplete & trouble free operation of Coal Handling System in an integrated manner.
•
Basic engineering, detail engineering and reference category of drawings, operating software and documents, in requisite copies, for approval of NALCO/ RITES. Further, the Tenderer nderer will furnish final basic & detail engineering drawings, manufacturing drawings of fast wearing items and non-standard non standard items, as built drawings, erection drawings/documents, operating software, operation and maintenance manuals in soft editable format.
•
Receipt of material, loading / unloading, storage, civil construction, complete erection, testing, commissioning, handing over of Wagon Tippler Complex to Purchaser, demonstration of performance guarantee and post commissioning services . Preparation and nd approval of erection survey / alignment schemes, grouting clearances, painting clearances, testing of welds, pressure testing protocols and other related site protocols.
•
Deputation of representatives of equipment suppliers and technology suppliers to site for supervision of erection, testing and commissioning.
•
Applying final finish coat of paint as per approved procedure & shades before handing over, first fill of lubricant & oil, special tools & tackles, mobile equipment, handling & hoisting equipmentt etc.
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•
Supply of all commissioning spares. A list of such commissioning spares shall be indicated separately. separately Tenderer shall quote separately for one year recommended spares with the main offer.
•
Progress reporting as per agreed formats, providing documentary documentary evidence of purchase orders on sub vendors with addresses of contact persons, attending all site progress review / engineering review meetings at NALCO, Angul or at RITES, Gurgaon / Bhubaneswar, opening an equipped site office with coordinator overseeing oversee all activities.
•
Arrangement of all erection equipment viz. cranes, hoists, winches, etc, and safety appliances as required for erection of plant & equipment. Appointment of safety officer by the contractor shall be included.
Specialized training of Purchaser’s personnel for operation, maintenance, for smooth handing over the plant. • Testing and cold trial run of systems/ sub - systems and integrated testing shall be carried out by the successful Tenderer on continuous basis for complete Coal Handling System along with associated facilities followed by commissioning. On successful commissioning of the various sub-systems sub systems of the Wagon Tippler complex, PG test of the entire Tippler House shall be carried out as elaborated in the relevant chapter. • Receivingg delivery of items at site, their proper storage, and handling at site, watch and ward services, removal of debris to a location specified by the Purchaser etc. Site shall be handed over to the Purchaser in clean and orderly manner to the satisfaction of the site engineers after commissioning of the project. • Getting Purchaser’s/ consultant’s approval for the drawings prepared by the successful Tenderer, obtaining required approval from statutory authorities, providing adequate personnel, equipment, tools & tackles for timely completion of the project. • For detailed scope of work and design parameters on various subsystems & facilities, the Tender Specification shall be referred to. This is a turnkey project for Installation of Wagon Tippler and conveyor conveyor system and all the facilities required for proper functioning of the wagon tippler and achieving the rated capacity shall be deemed to be covered in the tender specification, unless specifically excluded from the Tenderer’s scope. •
1.7.2
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SECTION 4 1.0
SYSTEM PARAMETERS, OPERATION & CONTROL PHILOSOPHY
1.1
The specifications as brought out in various Sub-sections Sub sections for mechanical equipment shall be applicable for the proposed wagon tippler and conveyor system and specifically to all mechanical including their operation & control philosophy. However, some specific parameters of the entire system as a whole and the major equipment are brought out as under.
2.0
PARAMETERS
2. 1
Conveyor System i. Rated Capacity (Guaranteed) : 1200 TPH ii. Design capacity : 1320 TPH iii. Belt width : 1200 MM iv. Belt speed : 3.5 m/sec. (approx.)
2.1.1
Belting and Pulleys Belts of conveyors shall be provided with latest belt weighing system to measure/record the quantum of coal falling on the belt and being carried by the conveyor conveyor system. The weighing system shall have adequate no of load cell., digitizer and intelligent terminal with printer facility for computerized zed print out of the weight. (a) Belt ratings with appropriate ratings shall be selected. (b) Minimum number of plies for belting shall be four (4) if possible, can be standardized with the type of belting available with NALCO. (c) For Pulley, following minimum parameters shall be adopted: (1.) Shell thickness : 16 mm (Min.) (2.) End disc plate thickness : 24 mm(Min.) (3.) Maximum allowable deflection of shaft at hubs : 5 Minutes (4.) Diameter for all drive pulleys shall be minimum 800 mm. Diameter Di of all other pulleys shall be minimum 630 mm The contractor shall obtain confirmation from belt manufacturers regarding the adequacy of the pulley diameters. 2.1.2
Wagon Tipplers (a) No. required: 1 (One) (b) Guaranteed tips per hour per tippler: 20
2.1.3
Side Arm charger (a) Nos. required :1 (one) (b) Guaranteed haulage : 60 fully loaded coal wagons (Box –N)
2.1.4
Apron Feeder (a) No. required : One (1)
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2.1.5
2.1.7
(b) Guaranteed (rated) capacity: 1200 TPH Apron Feeder E.O.T Crane (a) No. of unit : One (1) (b) Guaranteed (rated) capacity (Main/Aux.) : 25 T/5T Dust Control System The parameters for the dust control system specified hereinafter are intended for Contractor’s guidance only. Contractor shall provide adequately sized and effective dust control system, the performance of which shall be guaranteed by the Contractor as required in the Technical specifications. The performance guarantee test procedure is to be submitted by the Contractor. However, the capacity of the offered system system shall not be less than that specified below. (a.) Area Dust Suppression System at Wagon Tippler (1) Location : Wagon Tippler Top (2) Capacity of each nozzle : 2.0 lpm at 2.5 kg/ cm2 (3) Nozzle spacing. : 500 mm All nozzles to operate simultaneously in each wagon tippler area. (b) Dust Suppression System for other areas (1) Operation : Water sprayed with fogging nozzle (2) Location of spray : All coal loading and discharge point on the conveyor (3) Capacity / Pressure : 2.0 lpm / 2.5 kg/cm2 inlet of spray head
2.1.8
Service Water System Service water connections are to be provided in conveyor galleries & tunnels at 50 meter interval and one (1) no. on each floor of Transfer Point. (a.) Flow at each valve : 5 cub . m/hr (b.) Minimum discharge Pressure at tap point : 2 kg/sq.cm (c.) No of pumps : 2 nos. (d) No. of valves operated : 6 nos. simultaneously
2.1.9
Ventilation System A Mechanical Ventilation System • For Underground Areas a Minimum of 15 supply air changes and minimum 7 exhaust air changes per hour. • For other Areas a Minimum of 10 supply air changes per hour. B. Pressurized Ventilation System: System: Minimum 15 supply air changes per hour C. Air Conditioning System : • Adequate number of air changes to Maintain Maintain uniform temp. & humidity.
2.1.10 Chutes Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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Minimum clear cross section of chute shall be 1200 mm x 1000 mm (inside both ways).
2.1.11 Hoists Suitable hoists as specified elsewhere shall be provided for erection & servicing of all major equipment. The equipment to be covered shall include (but not limit to) all conveyor drive units, all pulleys, Apron feeder, sump pumps, various DS/service water/potable water pumps, gravity take up units, removal of equipment from tunnels, lifting of belt drum at all transfer tr houses. 2.1.12 All other equipment under the scope shall be suitable to the system capacities parameters as specified above. 3.0
OPERATION AND CONTROLS
3.1
This section is intended to cover design, engineering manufacture, supply, erection, testing tes and commissioning of the complete control and instrument panel/desk with annunciation panel, etc. as specified hereinafter complete in all respects, required for the system.
3.2
General Requirements The instruments and controls to be furnished and erected erected under this specification are as required for safe and satisfactory operation of the plant & equipment under Wagon Tippler and Conveyor System Package, as outlined under mechanical section and as specified elsewhere in the specification. For the equipment equipment and materials procured by the Contractor from his sub-vendors, vendors, the Contractor shall study the specification, safety requirements, interface drawings for such equipment and material in detail and shall coordinate his work with his subvendors and supply instrumentation and control to ensure suitability of the system.
3.2.1
Standards / Codes All construction, installation, workmanship, design & equipment shall conform to acts, rules & regulations of the jurisdiction within which the project is to be located, and to the current edition of the following or equivalent standards or codes, in so far as they apply: • American Iron & Steel Institute (AISI) • American Society for Mech. Engineers (ASME) • American Society for Testing & Materials (ASTM) • American Wire Gauge (AWG) • Institute of Electrical & Electronic Engineers (IEEE) • Instrument society of America (ISA) • National Electrical Code (NEC) • National Electrical Manufacturers Association (NEMA) • Bureau of Indian Standards (BIS) • Conveyor Equipment Manufacturers Association Ass (CEMA)
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•
Guideline for wagon tipplers issued by RDSO – G33 (Rev. 1) of May 2010 with latest amendments if any.
3.2.2
section shall be read in conjunction with Electrical Sub-sections. Sub sections. This Sub-section
3.3
Construction and Design
3.3.1
Construction Control desks/panels and annunciation system shall be provided as per the requirement of electrical Section. Annunciation’s, indications, electrical meters and instrumentation shall be provided as specified. Ammeters shall be provided on control desk for all a motors rated 30 kW and above and for all equipment.
3.3.2
Design The Contractor shall provide a comprehensive control indication and annunciation scheme for the plant & equipment under wagon tippler and conveyor system package and integrate the same with the existing control & monitoring scheme of the CHP. Contractor shall furnish a block diagram and write-up write up on the scheme proposed. The final scheme will be approved by the Owner/RITES and the Contractor shall be required to execute the approved scheme. scheme In general, interlocking shall be achieved through feed-back feed back signals from field equipment. A comprehensive Annunciation and Indication scheme shall be provided such that, it will be possible for the operator to locate and identify the fault from the display disp ace of Control desk. The scheme shall include the basic remote control instrumentation, indication and annunciation requirements as per various technical specification requirements. However, the Contractor may offer any alternative proposal which he considers considers to be equal, superior to the scheme as described in subsequent clauses below for achieving reliable and trouble free operation of the plant, for consideration of the Owner.
4.0 4.1
OPERATION AND CONTROL PHILOSOPHY The Wagon Tippler control room shall shall be located by the side of Wagon Tippler to accommodate control & monitoring equipment of wagon tipplers. It shall also have a battery room.
4.2
The existing coal handling system is being controlled from the following control points. The existing control ol philosophy of the coal handling plant is being described below for the contractor to understand the existing system and suitably plan integration of the controls and interlocks of the proposed control system of the wagon tippler package with the existing existin system.
4.2.1
Owner’s Existing Coal Handling Plant Control Room Operation of the CHP equipment is being controlled from the Owner’s CHP control room. (a.) Conveyors, feeders, flap gates, hydraulic couplings etc. (b.) Complete Dust Suppression system & service s water system. (c.) Ventilation system (group/individual control as required). (d.) In line Magnetic separators and Suspended Magnet (ON/OFF control with indication).
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(e.) Metal Detectors (ON/OFF control with indication). (f.) Belt weigher (ON/OFF control co with indication)
4.2.2
Local Control Panels Local control stations for following equipment shall be provided for (a) All conveyors (b) All gates (c) Electric hoist - wall mounted control box with pendent push button controls. (d) Wagon Tippler (e) Apron feeder (f) Sump Pump (g)) Dust suppression system for wagon unloading (h)) Hydraulic scoop coupling, if any. All the above local control panels shall be accessible and located near their respective equipment and shall be complete with all the required controls, interlocks, annunciation’s etc. Necessary controls, indications and annunciation’s for all the above equipment shall also be provided at main CHP Control Room.
4.2.3
In addition to the remote control of various equipments, local stop push button butto stations shall be provided for all equipment.
4.3
SYSTEM OPERATION
4.3.1
Typical Operation philosophy of the plant, in general, as elaborated below is for the information of the contractor to facilitate development of the control & monitoring scheme of wagon tippler and conveyor system package and integration with the existing control & monitoring system of existing CHP.
(a.) Coal flow path selection shall be done from Owner’s existing control desk to select conveying paths. (b.) The coal handling system operator operator will select any one of the paths from the main control desk. The flow stream path is then selected by positioning different flap gates at desired positions. Once the system is in the operation, the gates can not be moved from their positions and path. Flap gates which do not form f rm the stream in which coal flow is taking place, can be operated at any time. (c.) The Control system will be designed for both “Auto” & “Manual” operation of the conveyors in the selected path. Auto/Manual Selection shall be done from from Owner’s existing control desk. Auto Mode : In the “Auto” mode, the conveyors and related equipment will start sequentially when the “System Start” is activated. During stopping, when the “System Stop” Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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is activated, all conveyors will also stop sequentially sequentially (in the reverse sequence) allowing time delays for clearing the belts. Manual Mode : In Manual Mode, the operator will start the conveyor system, in the same sequence as in Auto mode from control desk. The operator will also stop the conveyor system,, by pressing "System stop" or individual “Stop” push buttons/command from control desk in the reverse sequence. System Start and System Stop PB’s and located on the Owner’s Control Desk. 4.3.2
Conveyor System
(a) Normally the operation of the apron feeder and the reclaim conveyor shall be controlled from main control room for evacuating coal from tippler hopper. (b) The approach of a Railway wagon rake to the plant shall be signaled (visual and audible) in the wagon tippler Control room as well as to the main coal handling plant control room, as soon as the rake come within 100 meters distances from the wagon tippler. (c) Each conveyor shall be protected against damage to the edge of the belt due to excessive sideways movement by providing adequate number of belt sway switches. In addition, each conveyor shall be provided with one (1) No. speed detection device (zero speed switch). The zero speed switches shall be designed to sense belt speed. failur by providing (d) All the conveyors shall be protected from roll back due to power failure mechanical / or electrical locking system. (e) The starting sequence of the conveyors shall follow a direction opposite to that of flow of material. The details of Coal flow diagram of the existing stage-I stage I CHP shall be furnished to the successful bidder. (f) Any individual equipment (belt conveyor etc.) should not be allowed to start unless the equipment immediately following the same in the direction of flow of material is already in operation. (g) Pull-cord cord switches shall be provided along the length of each belt conveyor, which shall enable the respective conveyor to be stopped immediately. Each pull operated chord switch and belt sway switch shall be tagged and shall be identifiable in the main control room. fore personnel sonnel working nearby when starting any conveyor. (h) Siren shall be provided to fore-warn (i) Interlocking of various conveyors shall be achieved with Flap Gate, limit switches and zero speed switches. if provided, is in “open” condition. This (j) Motors shall start only when the brake/rail clamp if-provided, signal al shall be obtained from limit switch provided for that purpose. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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(k) Once a conveyor trips, flap gate directing coal from this conveyor shall change over its position with a time delay and shall come back to the original position again, to prevent jamming of gate. (l) Where ever scoop type coupling provided for HT motors, the coasting time of respective conveyor, thruster brake, actuator selection and the chute size shall be so selected such that there is no spillage of coal from any downstream conveyors. 4.3.3
Interlocking a) The following conveyors / equipment are considered under interlock scheme :: (1.) All conveyors (2.) All gates (3.) Wagon tippler (4.) Apron Feeder b) The following equipment will not come under interlock of the conveyor scheme. (1.) All dust suppression systems & service water system. (2.) Ventilation systems c) All conveyors and equipment have local push button stations each consist of : (1.) Pos - I, Pos - II & stop button for flap gate (2.) Emergency stop push button (Red) for other equipment d) Belt scale is started when relevant conveyors are started. e) The dust suppression systems will be energized as soon as the conveyors are energized. f) Coal Handling plant shall be tripped in case of detection of fire. Necessary input contact shall be made available lable to the Contractor in the Owner’s main control room. g) Interlock for H.T. Motor : H.T. motors used will continue to run on no load by disengaging the fluid coupling in case of failure of any process interlock. The H.T. motors will however be tripped in case of any motor fault like O/L, high motor winding temperature etc. In addition, in case of normal stop command, after running of the system, motors will stop. h) The following are the various safety interlocks for the conveyors and other equipment. This list st is indicative only and the Contractor shall develop a comprehensive interlocking scheme. Conveyors a). Pull - Chord switch - not operated b). Belt sway switch - not operated c). Underspeed switch - closed at 90% speed of the conveyor within designed accelerating time. d). Motor protection - not tripped e). Local stop PB – reset f). Chute Block switch - not operated. g). Brakes for conveyor – not operated. h). Trip circuits healthy. i). Temp. of fluid coupling oil - not high
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Wagon Tippler a). Motor O/L - not tripped b). Local E-Stop PB - reset c). Stop PB in main CHP control room - reset d). All Limit Switches – reset e). All limit switches – not tripped Apron Feeder a). Motor O/L - not tripped. b). Local stop PB - reset. Flap Gates vel limit switches - reset. a). End of travel b). Torque limit switches - reset. c). Local stop - reset. 4.3.4
The lists of indications and audio-visual audio visual annunciation given in subsequent clauses are indicative only and the same shall be finalised during detail engineering.
4.3.5
Status indications in Mimic. Following individual status indications shall be provided in mimic with individual ON/ OFF /TRIP indications on HMI of PLC. (a.) Conveyor 'ON' (b.) Flap Gate/Rack and Pinion position. (c.) Belt scale flow rate indication indicati and totalizer. (d.) Belt sway switch operated for each conveyor (individual switch indication on CRT). (e.) Pull cord switch operated for each conveyor (Individual switches indication on CRT). (f.) Zero speed switch operated for each conveyor (g.) Wagon Tippler ‘ON' (h.) Apron Feeder ‘ON' .) DS/ SW/ VentON (System wise) (i.) Further Mimic lamps and Controls for HT and LT Breakers shall be provided on the control desk.
4.3.6
Annunication System: The Control desk shall be provided with adequate number of facia type annunciation windows for the following audio-visual audio visual fault annunciation purposes. Wherever group annunciation is provided, alarm status of individual equipment shall be provided on mimic.
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All audio visual annunciation of following parameters should be incorporated in the HMI of PLC. (a) 33 kV Breaker Trip (Group wise for each board) (b) 415 V MCC Breaker Trip (MCC wise) (c) Bus under voltage for each LT MCC (d) Following group wise annunciation annunciation shall be provided for transformers : (i) Buchholz alarm (ii) Winding/oil temperature high alarm (iii) Oil level low alarm (iv) Buchholz trip (v) Winding/oil temperature high trip (e) A.C Control Supply failure. (f) D.C. Control Supply failure. (g) Annunciation supply failure. (h) Both CPU fail (i) Stand by CPU in service (j) LT motor overload tripped (Group). (k)) Belt sway switch operated (Group) (l)) Pull cord switch operated (Group) (m)) Zero speed switch operated. (Group) (n)) Chute plugged (Group) (o) Wagon rake arrival. (p)) Wagon Tippler tripped (group) (q) Apron feeder. Dust suppression/service water system faults and trips (system wise) (r)Dust (s)) Water level low in tanks (group) (t)) Oil temperature of fluid coupling high (u) 20% spare windows For identification of the fault for a particular conveyor or equipment, status indication against that conveyor / equipment in the mimic will start fast flickering and the annunciation window will be blinking against that particular fault. In addition, a buzzer (alarm) will also start tart sounding. After acknowledgement of the fault, the buzzer will stop, but the fast flickering on the mimic and the steady glow on the annunciation window will continue until the fault is cleared and the Reset push button is pressed. When the fault is cleared cl and the Reset push button is pressed, the status indication of that conveyor / equipment on the mimic will start slow blinking if it is on selected path otherwise it will go off and the steady glow in the annunciation window will go off. However, pressing pressing of the Reset push button before clearance of the fault, will have no effect on the lamps. At the time of a fault, the faulty conveyor / equipment, as well as the preceding conveyors / equipment in the interlock sequence, will stop except H.T. motors for which only scoop coupling will be disengaged and motor will continue to run for process fault. In case of motor fault, H.T. motor will trip but the succeeding conveyors / equipment will continue to run. The status indication against the preceding conveyors conveyors / equipment will start slow Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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blinking while the faulty conveyor / equipment will be fast blinking. Start command shall not be initiated unless reset button in pressed after clearance offault. The sequence of operation of the annunciation system shall be as follows:follows:
Ann. Window Status indication Buzzer Ann. Window Status indication Buzzer
Status : Off. : Steady glow : Off. : Blinking. : Fast blinking : Sounding.
Press Accept PB. Ann. Window Status indication Buzzer
: Steady glow. : Fast blinking : Off.
Condition Normal :
Fault :
4.3.7
Press Reset PB (When fault is cleared): Ann. Window : Off. Status indication : i) Steady blinking (if on selected path) ii) Off (if not on selected path) Buzzer. : Off. Dust Suppression System
(a.)
Conveyors / Equipment 1. It shall be possible to spray the water on to coal stream only when corresponding conveyors/equipment’s are running with material at spray application points. 2. If a running pump trips stand-by stand pump shall start automatically. lly. It shall be possible to select any of the pumps as auto standby from main CHP control room. 3. Pump/pumps shall trip with a time delay, if discharge valves fail to open. Suitable pressure/flow switch shall be provided to sense this condition. 4. Pumps shall trip in case of low level of water in tank. 5. All feeding pumps to tank shall trip in case of high-high high level in tank. 6. All the controls shall be through control desk.
(b.) Wagon unloading 1. System shall be operated from local control panel. 2. Dust suppression system shall be provided to cover the WT Hopper. 3. Pumps shall be started manually or from control panel.. If any of the pump/pumps trips, stand-by by pump/pumps shall start automatically. It shall be possible to select any of the pumps as auto stand - by. 4. Pumps shall trip in case of low level of water in tank. 5. Following annunciation’s shall be provided at local control panel. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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(i) Motor electrical protection operated (Group) (ii) Discharge water pressure low (Group) (iii) Water level low in tank (Individual) 6. Following individual indications shall be provided at local control panel. (i.) Motor ON/OFF/TRIP (ii.) Discharge pressure healthy (iii.) Water level high in tank. 4.3.8
Sump Pumps (a) Sump Pumps shall start and stop by the level switches in the sump automatically. Further manual override start / stop push button shall be provided locally on ground level. auto (b) Any of the pumps can be selected as auto-standby. (c) If the sump level continues to be high even after the first pump is under operation second pump shallll start automatically. (d) The following indications for sump pumps shall be provided on local Control Panel. (1.) Water level high (2.) Motor ON/OFF/TRIP.
4.3.9
Wagon Tippler Wagon Tippler shall be controlled from the local control panel suitably placed. Requirement Require of operation as described elsewhere in the specification shall be complied with. Following indications shall also be provided on the local control panel: (a.) Motor ON/OFF (b.) Motor O/L protection operated (c.) Brakes applied (if provided) (d.) Hydraulic power pack indications as applicable.
4.3.10 Flap Gates All flap gates shall be motorised and remote controlled from the main control desk. Their position shall be indicated on the mimic of main control room. 4.3.11 Service water and Cooling Water Wa (a) These pumps shall be started from main CHP control room (b) Pump shall trip in case of low water level in tank. (c) Following individual inputs shall also be provided to PLC system for alarms/indications : (1.) Motor ON/OFF/TRIP (2.) Discharge water er pressure low (3.) Water level low in tank (4.) Water level high in tank 5.0 WAGON TIPPLER GENERAL Rotaside / Rotary wagon tippler shall be furnished complete with all structural members, tippler platform, tipping mechanism, tippler drive motors, brakes, couplings, shafting and all Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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automatic controls for positioning, tipping and discharging the entire contents contents of the wagons into the hopper. 5.1
Wagon Unloading System
5.1.1
The rake comprising of specified maximum60number maximum number of wagons shall be pushed into the reach of in-haul haul equipment by a locomotive. Further placing of wagons over tippler platforms and carrying away away the empty wagons shall be accomplished with the help of a side arm charger under scope of bidder.
5.1.2
Wagon unloading equipment shall be suitable to handle any type of wagons being used by Indian Railways for transportation of coal. Thus side arm charger and and wagon tippler shall be suitable to handle all standard broad gauge (1676 mm) wagons of RDSO design used by Indian Railways conforming to latest revision of IS: 10095.
5.1.3
Maximum moving dimensions of locomotive & wagon as per Indian Railway norms shall be adopted for providing clearances with respect to structures, equipment and tippler arrangement.
5.1.4
Complete wagon tippler and accessories shall have the approval of concerned Indian Railway Authorities and RDSO. Further, the contractor shall submit to the Owner detailed drawings of wagon tippler and accessories including civil and structural drawing only after getting the same approved from the concerned Railway authorities.
5.1.5
The bidder shall obtain all statutory approvals from the relevant Railway authorities, authorit before the wagon tippler complex is put into operation. Any statutory payment charges, to be made to the concerned authorities shall be to Bidder’s account. It is the responsibility of the Contractor to carry out any modifications as required by the Railway Railway authorities, at no extra cost to the Owner.
5.2
Wagon Tippler Hopper
5.2.1
The wagon tippler hopper shall be of RCC construction and adequately sized to accommodate the coal load for atleast two (2) nos. 8 wheeled wagons of RDSO design used by Indian ian Railways. For effective volumetric capacity computation of the hopper, the angle of repose of coal shall be considered as 37°. The minimum valley angle of the hopper shall be considered as 60°. The hopper shall have opening below which apron feeders shall sh be provided to evacuate coal from the hopper and feed onto associated belt conveyors below. Complete inside surfaces of the hopper shall be provided with 50 mm thick guniting. Further it shall be possible to empty out all the coal, without any dead stock stock from the hopper.
5.2.2
Steel gratings of mesh size 300 30 mm x 300 mm over wagon tippler hopper shall be provided. The gratings shall be built of minimum 200 mm x 36 mm thick flats. The hopper and gratings shall be designed for movement of front f end loader/bulldozer over them. Bull-dozer Bull weight shall be considered as about 35 T.
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5.3
CODES AND STANDRDS The design, manufacture, inspection and testing of Wagon Tippler shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Wagon Tippler shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall shall also be accepted. Nothing in this specification shall be constructed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision so the Engineer shall be final and binding. bindi
5.4
DESIGN REQUIREMENT Keeping in view Technical guideline issued by RDSO (Research & design services organization )G 33 Rev.01 issued on May’10 & effective from Dec’10, the specification of wagon tippler along with apron feeder to be designed as under: a) Wagon tippler capacity : 25 Tips per Hour b) Load handling capacity of wagon tippler : 140 Ton
5.4.1
The wagon tippler shall be suitable to unload unloa a coal wagon.
5.4.2
During each cycle of operation, the tippler shall be capable of holding, completely unloading and replacing the wagon to its original position without damage to the tippler or the wagon or the track.
5.4.3
The tippler shall be suitable for continuous operation, 24 hours a day, round the clock.
5.4.4
The wagon tippler structure shall be designed to conform to the requirements of Indian Railway’s “Research, Design and Standards Organisation, (RDSO) - G 33 Rev.1 ” with regard to the nature of loading, impact factor and allowable stresses. It shall be the sole responsibility of the contractor to ensure that each and every component of the wagon tippler is adequate in rigidity, strength and of heavy duty construction of first class quality to guarantee against failure or major damage, assuming proper maintenance and usage. The tippler shall be designed to allow passage of all standard broad gauge (1676 mm) Indian Railways diesel locomotives over tippler table at restricted speed.
5.4.5
The wagon tippler shall be suitably counter balanced at each stage of operation so as to require minimum driving power.
5.5
WAGON TIPPLER WEIGHING SYSTEM
5.5.1
This specification calls for an electronic static weighing system to measure / record the quantum of coal, wagon wise on the wagon tippler table before & after tippling. The weighbridge with adequate no. of load cells shall be provided beneath the wagon tippler ti
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platform with a minimum accuracy of 1% of the gross weight of the wagon. The platform shall be freely supported on the weigh bridge before and after tipping for accurate weighing. The wagon tippler weighbridge shall be designed to statically weigh the th wagons in an uncoupled condition. The system shall comprise of a weighbridge, a tippler table, load cells, weight digitizer and an intelligent terminal with printer with the facility for computerized printed output of data gross weight, tare weight, wagon wagon no., time, date etc. the weighbridge shall be chosen to accommodate all types of wagons as per RDSO guidelines to move coal. The weighbridge shall be supported on minimum 4 nos. compression type load cells mounted on free motion structural unit assembly. motion weigh scales in both in-haul in and out-haul haul tracks shall be provided Alternatively, in-motion for the purpose. The load cells shall be suitable for dusty environmental conditions. The calibration of the weigh bridge shall be the scope of the bidder. The bidder bidder shall co-ordinate co with statutory authority to get the necessary stamping & other requirements. 6.0
CONSTRUCTION REQUIREMENT
6.1 6.1.1
Cradle The cradle shall consist of a pair of heavy welded steel plate sections reinforced with stiffeners and connected cted by side bearer beams pivotally attached, each section being fitted with a massive trunion shaft carried in bronze bushed cast steel bearings on each side, bolted to steel pedestal carried on concrete pedestals. Circumferential driving rack shall be rigidly gidly bolted to the peripheries of the sectors. The sectors shall be made of cast steel. Necessary features of safety against coming down of wagon tippler in the event of failure of one of the drive pinions and / or gear racks shall be provided and the same sam shall be clearly indicated in the bid.
6.2 6.2.1
Rail Table The rail table shall be constructed of rolled steel joints with standard steel rails (52 kg/metre) mounted on it. The table shall be pivoted from arms extended from the sectors. The table shall be covered with chequered plates between the rails.
6.3
Feeders and Clamps
6.3.1
The wagon shall be clamped automatically by hydraulic system and firmly on the cradle during the tipping without any damage or undue pressure on any part of the wagon and no hand adjustment of any sort shall be necessary. Sliding side stop pads shall be of resilient material to prevent damage to either the wagon or the stops.
6.4
Spill Plate
6.4.1
Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting material into the tippler hopper.
6.5
Driving Gear Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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6.5.1
Multiple pinions meshing with cast steel racks bolted to the end sectors shall impart drive through hydraulic drive with each pinion drive through slow speed high torque hydraulic hydr motors using gear boxes as applicable. Suitable oil coolers shall be provided for hydraulic power pack. Suitable dust protective cover shall be provided.
6.6
Brake
6.6.1
An automatic electro hydraulic brake shall be furnished to hold the tippler in any position with the load and against any movement except that provided by drive.
6.7
Limit Switches
6.7.1
Limit switches of suitable type which can be readily adjusted to give the desired tippling angle shall be provided. An emergency over tip limit limit switch operated by a striker on the tippler trunnion shaft shall be furnished.
6.8
Ballast
6.8.1
Ballast necessary for counter weight and balancing the tippler shall be provided as per the requirement.
6.9
Lubrication
6.9.1
All bearings shall be properly lubricated. Grease nipples and reservoirs shall be furnished where necessary.
6.10
Guards
6.10.1 All gears inside machinery pits and other moving parts shall be securely guarded. 6.10.2 All necessary base plates, guide plates, chequered plate covering for drive pit and any other pits, all required fixing materials, inserts and sleeves shall be furnished. 7.0 7.1
DATA SHEET GENERAL Wagon Type Moving Profile No. of tips (guaranteed) Designed Rail Gauge Weigh bridge Duty
7.2
: All types of wagons in coal transport used by Indian Railways to move coal (as per latest test RDSO guidelines) : As per IR norms. : 20 per hour. : 25 Tips per Hour : 1676 mm. : Load cell type : Continuous 24 hrs.
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A.
Wagon Tippler Hopper Construction Size No. of openings
: RCC Construction. : To accommodate atleast 2 nos. 8 wheeled wagons. wagons : One (1)
Angle of repose of coal for wagon tippler hopper sizing Lining Steel Grating (i) Mesh size (ii) Grating Section B
Wagon Tippler Type Tipping angle
Duty Requirement Counter balancing Cradle Driving Gear (i) Racks (ii) Pinion Rail Table Drive Brake Clamping Top & side stops
: 37° : 50 mm thick guniting. : 300 mm x 300 mm : 200 mm x 36 mm thick flats.
: Rotaside / Rotary type (As per latest RDSO guidelines) : The Wagon Tippler shall be suitable to unload Coal Coa wagons. The angle of tippling shall conform to RDSO G-33 G (Rev – 1) Technical pamphlet for requirement of tippler installation for approval by RDSO. : Continuous operation : Suitable to keep power requirement at minimum. : Heavy welded steel plate construction trunion mounted. : Cast steel rack sections bolted to end sectors. : Multiple pinions meshing with rack. : Rolled steel joists with ith steel rails mounted on it. : Hydraulic motors. : Electro hydraulic thruster operated. : Hydraulically operated : Self aligning type made of resilient material.
8.0
SIDE ARM CHARGER
8.1
GENERAL
8.1.1
Side Arm Charger shall be furnished complete with travel rails, drive equipments and associated accessories.
8.1.2
The rake comprising of specified maximum number of wagons shall be pushed into the reach of inhaul equipment by a locomotive. Further placing of wagons over tippler platform and moving out the empty wagons shall be accomplished with the help of side arm charger. c
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8.2
CODES & STANDARDS The design, manufacture, inspection and testing of Side Arm Charger shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed and all norms nor stipulated by RDSO- G 33 Rev.1. The Side Arm Charger shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding.
8.3
DESIGN REQUIREMENT
8.3.1
A single module of side arm charger shall be used for inhaul and outhaul operations. Thus, side arm charger shall be used for indexing forward the rake of 60 nos loaded wagons, placing decoupled wagons on the tippler table and out hauling hauling the empty wagons.
8.3.2
The rake of 60 loaded wagons will be brought by locomotive and placed on the retipping line such that the leading wagon will be within the reach of the side arm charger. Now the side arm charger will be coupled to the leading wagon, wagon, pull the rake of 60 nos. loaded wagons towards tippler table. The first wagon will be decoupled manually from the rake and signal will be given to the side arm charger operator that the wagon is de-coupled. de Now the leading wagon will be placed centrally centrally onto the tippler table by side arm charger, (simultaneously ejecting the empty wagon from the tippler table). After the loaded wagon is placed on the tippler table, the arm is de-coupled de coupled from the loaded wagon. Adequate clearance between tippler table and and empty wagon shall be ensured. The side arm charger will stop at the end of its strokes, the arm will be swung vertically-up vertically up and the machine will move towards in-haul haul direction and occupies the initial position. In the meantime, the tippler will tip the loaded wagon placed on the tippler table and return to its original position. Before tippling operation of wagon tippler is completed, the arm of the side arm charger will be swung to horizontal position and will be coupled to the rake of remaining loaded wagons at waiting position just before the tippler table and is now ready for the next cycle to start. After the tippling operation of wagon tippler is completed the cycle will be repeated.
8.4
TECHNICAL REQUIREMENTS
8.4.0 8.4.1
CONSTRUCTION REQUIREMENT The Side Arm Charger shall be suitable to handle60 handle number of loaded wagons. wagons The pusher arm shall be vertically rotatable arm mounted on a carriage running back and forth parallel to the train track.
8.4.2
The arm shall be raised to clear the movement of wagons wagons and locomotives during reversing back of positioner carriage and shall be lowered for engaging the head of the arm with the wagon coupler for index strokes.
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8.4.3
The arm shall be raised and lowered by means of hydraulic cylinder mounted on the carriage. iage. Suitable means shall be provided to prevent damage to the arms should the arm be accidentally lowered into the side of wagon.
8.4.4
The arm shall be of robust construction either of cast steel or of heavy duty fabricated steel for the required duty.
8.4.5
The construction of the head assembly of the push arm shall be such that no damage is suffered by the couplers of wagons and engagement of arm over the coupling assembly as well as transmittance of indexing forces to accelerate, run and decelerate the train during the positioning cycle shall be very smooth.
8.4.6
The carriage frame shall be a suitable fabrication assembly of large proportions massive enough in strength and rigidity for the required duty.
8.5
Travel Carriage Drive System
8.5.1
The travel carriage with push arm shall be propelled to and fro, parallel to train track through hydraulic motor driving through a gear box and EHT brake.
8.5.2
The rating of the drive equipment and its characteristics shall match with indexing forces required quired to be exerted in varying amounts depending upon train dynamics and to suit haulage of 60 wagon loaded rake.
8.5.3
The travel carriage shall ride on vertical bearing wheels and will be guided by horizontal bearing wheels by suitably transmitting the thrust load from the positioned arm to the foundation. The wheels/rollers shall be of forged steel and shall run on the rails supported over the RCC pedestal.
8.5.4
Cushioned emergency bumpers (buffers) shall be provided at the forward and return end of carriage travel run for protection. These shall be designed to arrest the machine without undue shock in case the machine exceeds its extremities because of any mal-operation. mal
9.0 9.1
DATA SHEETS GENERAL : 1 (One) no Quantity No. of wagons to be handled By each side arm charger at a time : 60 No. of tips by wagon tippler : 20 (min.) per hour (guaranteed) : 25 per Hour (designed) DESIGN & CONSTRUCTION REQUIREMENTS
9.2
Arm Arm Drive
: Robust construction either of cast steel or heavy duty fabricated steel. : Hydraulic cylinder
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Carriage Frame Travel Carriage drive Motor Travel brake Bearings for sheaves 10.0 10.1
: Single fabrication assembly. : Hydraulic : Integral part of hydraulic motor : Anti friction bearings.
APRON FEEDER GENERAL Apron feeders complete with all accessories shall be furnished for wagon tippler hoppers as specified.
10.2
CODES & STANDARDS The design, manufacture, inspection and testing of apron feeders shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The apron feeders shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performancee than those specified, shall also be accepted. Nothing in this specification shall be constructed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer eer shall be final and binding.
10.3
DESIGN REQUIRMENTS Apron feeders shall be of robust construction & designed for handling ROM coal as specified and without any choking particularly during rainy season when coal is sticking. A drible conveyor shall be provided for proper clean up. The pan and chain shall be of proven design and shall be with adequate factor of safety.
10.4
CONSTRUCTION REQUIREMENT The frame shall be manufactured from rolled steel section welded and bolted together to form a rigid structure. cture. The roller shall be life time lubricated and shall be manufactured from alloy steel. The chain Link shall be forged steel. Pins and rollers shall be of hardened steel. The chain link shall be bolted to the pans. Apron/pan shall be of suitable thickness thickn which shall be constructed out of fabricated MS with wear resistant liner plate or special alloy steel without any liner plate for the duty requirement. The pan would be fitted directly to the chain attachment. The head and tail end shall be of sturdy steel construction suitably stiffened. The sprocket shall be made of cast alloy steel with case hardened teeth or forged steel. The traction wheel shall be made of cast steel with case hardened surface. Tensioning arrangement with sufficient travel shall be be provided for the tensioning of the chain. chain Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, stringers, deck plates etc. shall be provided.
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10.5
DATA SHEET Capacity (TPH) Angle of Installation Chain Link Apron pan Traction wheel Rollers
11.0 12.0
: 1500 MTPH ( Design) 1200 MTPH ( Rated ) : Horizontal : Forged alloy Steel : MS fabricated with wear resistant plate or special alloy steel . : Cast Steel : Forged Alloy Steel
No sizer or crusher is required. DRIVE EQUIPMENT GENERAL Suitable Drive Chain Equipment’s like electric motors, gearboxes (where applicable), fluid couplings (where applicable), flexible couplings and other accessories shall be provided for all the belt conveyor systems, wagon tippler, tippler, side arm charger, apron feeders, various pumps of dust suppression system, fans for ventilation system, monorail electrical hoists and other equipment’s specified in this specifications. Various requirements as spelt out in the Technical Specifications for for individual equipment’s shall be taken into consideration while designing the associated drive chain equipment’s.
12.1
CODES AND STANDARDS The design, manufacture, inspection and testing of Drive Equipment shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment in to be installed. The Drive Equipment’s shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which whic ensure equal or higher performance than those, specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, specification, the decision of the Owner shall be final and binding. IS:3688 : Dimensions for shaft ends IS:3681: General plan for spur & helical gears IS:7403 : Code of practice for selection of standard worm and helical gear boxes
12.2 DESIGN AND CONSTRUCTION REQUIREMENTS 12.2.1 GEAR BOXES 12.2.2 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. 12.2.3 The gearboxes shall be designed for 24 hours continuous duty and gear boxes shall have appropriate thermal rating. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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12.2.4 Thee gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction units or spiral bevel speed reduction units conforming to suitable Indian Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest revision. Above Ab 40 kW drive rating, all gearboxes shall be helical or bevel helical type only. 12.2.5 Recommended oil grade shall be compatible with gear internals like material of bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick, drain plug etc. 12.3 COUPLINGS 12.3.1 Flexible / Rigid Couplings Approved type of couplings shall be used for power transmission depending upon duty requirements. The design of the coupling shall be such that it can take shock and misalignment without sacrificing its efficiency. Geared type flexible coupling shall be used on low speed side ide for all conveyors and other drive chains where gear box is provided. Other couplings in the drive chains shall be either rigid or flexible type, depending upon the requirement of equipment design and shall be finalized during detailed engineering. 12.3.2 Fluid Couplings Fluid couplings shall be provided in all the drive machinery for wagon tipplers & associated belt conveyor systems if the actual power requirement at motor output shaft is more than 40 kW. The fluid coupling for LT motors shall be of traction traction type. Cooling water coils for traction type fluid coupling shall not be accepted. Scoop tube type fluid coupling shall be provided for conveyors with HT motors. Suitable electrically operated actuators shall be provided for scoop tube operation from local as well as remote. Suitable provision for alternate manual operation shall also be kept. Separate pump with motor shall necessarily be provided for circulating the fluid coupling oil through oil cooler. Independent arrangement for forced cooling water water supply using 2X100% capacity pumps to oil cooler shall be provided by Contractor. Suitable interlock using flow switches shall be provided in both oil as well as water lines to trip the drive motor in the event of flow in either lines falling below/ acceptable eptable levels. Suitable pressure indicators and flow indicators shall be provided in the cooling water lines along with all-relevant all relevant valves, strainers and accessories. Necessary isolation valves shall be provided in the oil / water line for maintenance of any equipment in the line. Necessary interlock shall also be provided so that the HT motor cannot be started from remote / local unless position of scoop tube permits no load start of the motor. Tripping of downstream equipment while the system is under normal n operation shall result in scoop tube re-positioning re positioning to permit no load run of the concerned HT motor. Temperature switch shall be provided in the oil circuit and shall trip the system in case of high oil temperature. Selection of rating & speed of actuator actuator for scoop type fluid coupling shall be made taking into consideration the coasting time of downstream and upstream conveyors and the engagement/disengagement time achievable. The scoop tube operation must be such so to ensure quick draining out of oil oil from the operating circuit, by providing a double speed motor.
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12.4
DATA SHEET: DRIVE EQUIPMENT GENERAL
12.4.1
Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for Electric Motors For conveyors of belt conveyor systems and belt for In line magnetic separator: a) *120% 120% of actual power at drive motor output shaft at specified design capacity b) WT, SAC, apron feeders: *110% 110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity. c) Mono-rail rail hoists (travel and hoisting), various pumps of DS systems, service water systems, cooling water system, potable water system and sump pumps: *110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity. Ventilation Fans: *110% 110% of actual power requirement at drive motor output shaft at d) guaranteed (rated) capacity. In case of belt drive, the efficiency of transmission shall be considered as 95%. *The The actual power at drive motor output shaft shaft shall be calculated after considering all the losses of down the line equipment’s of the drive train. 1.0 Drive Equipment Rating a) For Conveyors : 120% of actual design requirement b) Other Equipment 1 x 100 % duty: 120% of actual design requirement c)) Other Equipment 2 x 50 % duty: 110 % of actual design requirement 2.0 DESIGN & CONSTRUCTION REQUIREMENT 2.1.0 Gear Box 2.1.1 Type (a) Below 40 KW: Helical, worm, bevel as per requirement without cooling coil (b) Above 40 KW: Helical / bevel helical without w cooling coil 2.1.2
Service Factor: As per accepted engineering practice / manufacturer's recommendations 2.1.3 Ambient temperature for Thermal rating: 50o C Minimum 2.1.4 Mounting: On Machined/Ground Surfaces 2.1.5 Output Rating: a) For belt conveyor systems @ Service factor X {1.2 times the actual power requirement at drive pulley shaft at design capacity} b) For other equipment @ Service factor X {1.2 times the actual power requirement of the driven equipment } @ Service factor shall include all the components considered by the supplier and should be clearly indicated in manufacturer’s gear box selection catalogues. 2.1.6 Duty: 24 Hrs. Continuous 2.2.0 Flexible Couplings: 2.2.1 Type: Geared capacity. 2.2.2 Rating: Not less than han motor rating.
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2.3.0 Fluid Couplings: For all motors having rating more than 40 KW. 2.3.1 Type (a) L.T. Motors: Traction type (b) H.T. motors: Scoop tube type. 2.3.2 Rating: Not less than motor rating 13.0 13.1
EOT CRANE GENERAL An E. O. T. crane complete with all accessories shall be furnished for maintenance at wagon tippler house. The design, manufacture, supply erection and commissioning of EOT crane complying with all the currently applicable statutes, regulations and safety codes in the locality loca where the equipment is to be installed. The EOT crane shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which insure equal or higher performance than those specified, shall also be accepted. accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding.
13.2
EQUIREMENTS AND CONSTRUCTION REQUIREMENTS DESIGN REQUIREMENTS The crane shall be generally of box type double girder construction and shall designed for appropriate class of duty in accordance with BSS: 466/1960 and or IS:3177 to meet the installation and maintenance of wagon wagon tippler and the associated equipment. The bridge should comprise of two main girders with two out riggers and the end carriage built up from mild steel channel with adequate diaphragms or stiffing plates. Each bridge girder shall be fabricated and dispatched dis without any spliced joints. Box Girder & End carriage joints shall preferably have fit bolts. For all bolted joints the holes are to be drilled and reamed and bolts are to be force fitted. Hand railing shall be fitted on both sides of the end carriages and throughout the length of the platform (height of 1.1m) parallel to girder. Size of the hand rail shall be not less than 25 mm bore heavy gauge steel pipe. The vertical pipes shall have flanges at the bottom for proper support. Suitable hand railing railing should be provided on Cross Travel Trolley also. All Rotating parts & Overhang parts shall be provided with suitable guard. The end carriages shall be of approved design, with L type Brackets of substantial construction and ample stiffness built up of mild steel sections securely welded. The end carriages of the crane are to be mounted on double flanged wheels of approved diameter in accordance with IS: 3177. Number of wheels on each side of the crane shall be 2
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Nos (Total 4 Nos in the Crane for for Long Travel motion) The Wheel shall be of forged steel having composition as Cr 55 Mn 75 (EN 9) hardened to 300-350 300 350 BHN with minimum depth 10mm confirming SAE 1055 / IS 1570 & shall be fitted with roller bearings with dust proof seals. For lubrication, Grease nipples shall be provided at convenient points. Twin drive system to be adopted for Long Travel of E. O. T. in the bay. One wheel in each carriage is to be driven by forged steel gears through a motor mounted on or adjacent to the carriage. Long travel mechanism shall be provided with, a thruster brake on each individual drive of the track wheels. These brakes shall be such that it can be operated from both the control desk as well as remote control. The brakes shall be of post type with hinged hing shoes, lined with good quality reinforced bonded brake lining and suitable for easy of adjustment of the wear on lining.
13.3
An independent additional mech. / electrical operating brake are to be provided with LT motion to stop the crane immediately in case ca of power failure. DATA SHEET 13.3.0 13.3.1 13.3.2 13.3.3 13.3.4
CAPACITY AND LEADING DIMENSION Safe Working Load: Main Hoist - 25T Safe Working Load: Aux. Hoist - 5T Duty as per I.S.3177 (Latest Amendment) SPEED OF MECHANISMS: (a) Main hoist Hoisting / Lowering (b) Aux. Hoist Hoisting / Lowering (c) Cross Traverse (CT) Forward/ reverse (d) Long Travel (LT) Left / Right
- 6 M/Min - 8 M/Min - 10 M/Min - 30 M/Min
13.3.5 (a) Normal Span: Actual span & other dimensions as required as per structural steel shed of wagon tippler shall be evaluated by the bidder and confirmed in the bid. 13.3.6 (b) RailCenter to Center: Bidder to confirm 13.3.7 Gantry Rail heights above floor level: Bidder to confirm 13.3.8 Hook lift above floor floor level to be provided: Bidder to confirm depending upon actual site condition 13.3.9 Type of Hook - Shank type 13.3.10 Available head height above rail top: to be confirmed by Bidder 13.3.11 Available side clearance from gantry rail center: Bidder to confirm 13.3.12 Location Wagon tippler shed, Bay Length & Width: Bidder to confirm 13.3.13 Electric power supply - 415 Volt, 3 Phase, 50 HZ A.C. Supply 13.3.14 Gantry rail size - Bidder to confirm.
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14.0 14.1
MONORAILS AND HOISTS GENERAL Suitable handling arrangements shall be provided for all equipment’s included in Contractor’s scope to transfer the equipment to maintenance area within the building and/or to transfer the equipment outside the building upto ground level for further transportation by the Owner. For this purpose Contractor shall provide monorails and hoist blocks with cross travel facility.
14.1.1 CODES AND STANDARDS The design, manufacture, inspection and testing of Monorails and Hoists shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Monorails & Hoists shall conform to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal al or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner/RITES shall be final and binding. • • • • • • 14.2
IS:3938 : Specification for Electric Wire Rope Hoist IS:3832 : Chain pulley blocks IS:2429 : Round steel short link chain IS:6216 :Short link chain grade 80 IS:8610 :Points hooks with shank for general general engineering purposes IS:210 : Cast Iron Castings
DESIGN REQUIREMENTS
14.2.1 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with the exception of hoists for GTU and bend pulleys motor operated hoist blocks for both long travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both travel and lift. For hoists for GTU’s and bend pulleys clause no. 1.02.18 shall be referred to. All monorails coming out of the buildings shall be provided provided with electric hoist blocks, irrespective of load and lift. Minimum 3 meter length of Cantilever shall be provided in monorails coming out of the building to lower the equipment to ground level clearing the building sidewalls and any other facilities beneath beneath the floor upto ground level. 14.2.2 The exact lift/travel and the number of the hoisting mechanisms and the mode of lifting equipment’s to various floors of the buildings shall be as decided by the Owner/RITES Owner at the time of detailed engineering. Use Use of single hoist shall be avoided for handling more than one equipment. Clear height shall be maintained when handling one equipment over other, in such case dismantling of any equipment shall not be permitted. The center line of monorail shall not deviatee by more than 500 mm from the center of gravity of any equipment that is to be lifted. Contractor shall take clear note of the fact that the number and monorail hoisting systems shall also be decided considering the movement of the equipment being Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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lifted over/by the side of other equipment’s without removing the later. The necessary levels of floors in various buildings shall be decided considering the above requirement. g level. 14.2.3 Monorails shall be extended outside the building to handle the equipment to ground For monorail/hoist routed inside the buildings, suitable machinery well and removable handrailing and grating shall be provided on various floors of buildings, as necessary, to handle the equipment. 14.2.4 Electrically operated monogirder type type hoists shall consist of following major components. a) Electrically operated trolley complete with drive motor (Trolley travel speed maximum 15 m/min.). b) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting speed maximum 6m/min.). c) Limit switch to prevent overhoisting, over lowering and over travel. d) Festoon arrangement of feeding power to trolley assembly. e) Erection hardware. f) Pendent control station suspended from hoist. g) Control Panel mounted on wall. designed and constructed in accordance with the latest revision of 14.2.5 The electric hoist shall be designed IS:3938 and shall be suitable for duty class 2. 14.2.6 For electric hoists, trolley movement and hoisting shall be effected by using two separate motors. Motors shall be as per technical requirements requirements discussed elsewhere. However the motors shall be suitable for 150 starts per hour at 40% CDF. 14.2.7 Trolley for motorized / manual cross travel shall be designed to accommodate a wide range of I beams and shall be capable of travelling on straight as well as curved monorails with the design being such to maintain uniform distribution of pressure on the flanges. 14.2.8 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which shall be driven through motor. 14.2.9 Wire rope shall be of pre-formed pre formed type, hemp cored, regular lay 6/36 construction with a breaking strength of 160 -175 175 kgf/ sq. mm. Reverse bend of ropes is not acceptable. Minimum number of falls of rope shall be four (4). 14.2.10 All gears and pinions shall be of hardened and tempered steel with machine cut teeth in metric modules. Surface hardening of steel is not acceptable. 14.2.11 All running shafts and wheels shall be fitted with roller bearings with a rated life not less than 20 years based on equivalent eq running time as per IS:3938. 14.2.12 An electromechanical brake shall provided for hoisting as well as cross travel. Brake lining shall be of asbestos. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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14.2.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210. n pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to 14.2.14All chain IS:2429 grade 30 pitched and polished and the load chain to IS:6216 grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be as per IS: 8610 & with antifriction bearing for bottom look. 14.2.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and shall be selected to lift heaviest piece of equipment. Further, it shall be possible to handle any equipment without disturbing disturb other equipment. 14.2.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and designed to ensure effective operation of hand chain. Further, suitable local brake shall be provided as per IS:3832 to arrest and sustain loads load in all working positions. 14.2.17 The velocity rates, effort on chain required to raise the safe working load and travel and speed shall be within the limit specified in IS:3832. Proof load test shall be carried out as per IS:3832. Balance requirements shall be as discussed in earlier clauses pertaining to electric hoists. 14.2.18 Hoist for Gravity Take up arrangement and bend pulley. For handling bend pulley, take-up take up pulley and counter weights following hoisting arrangement shall be provided: (1) For handling bend pulleys, hooks of adequate capacity shall be provided at the top of gallery. Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity shall also be provided for the entire coal handling plant for handling bend pulleys. (2) For handling take-up up pulleys, manual hoist along with mono rail beam of adequate capacity having cross travel, arrangement shall be provided at bottom of gallery to handle take-up take pulley only of conveyors. (3) For handling take-up up weight, a separate manual manual hoist with mono rail beam of adequate capacity shall be provided to hold complete counter weight (inclusive of all counter weight blocks). This hoist shall be provided for holding the counter weight and shall be located in the zone of counter weight travel. 14.3
CONSTRUCTION REQUIREMENT
14.3.1 The hoist mechanism shall consist of a grooved rope drum driven by electric motor through gears. Each end of the rope shall be anchored to the drum in such a way as the anchorage is readily available for maintenance. maintenance. Each rope shall have not more than two (2) full turns of the drum when the hook is at its lowest position and one (1) spare groove when the hook is at its highest position. The leading rope taken by the drum should not slope sideways when slack and nd it should not be caught between the gear wheel. 14.3.2 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel.
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14.3.3 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be mounted on antifriction iction bearings and shall be easily removable for repair/replacement. 14.3.4 The load hook shall be swiveling type forged circular shank section and shall confirm to IS:8610. points shall be grouped 14.3.5 All gears and bearings shall be lubricated by grease. All lubricating points together in easily accessible position. 14.3.6 The bottom block shall be of enclosed type and shall have guard against rope jamming in normal use. It shall have standard forged swivel shank hook fitted on antifriction thrust bearing.. Lock to prevent hook from rotation and locking arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom block shall be provided with antifriction bearings. 14.3.7 All parts requiring replacement/inspection/lubrication shall be accessible without need for dismantling of other parts/structures. 14.3.8 All components of hoists of identical capacity and duty shall be interchangeable. 14.3.9 Hoists shall have permanent inscription in English on each side readily recognizable from floor level stating safe working load. 14.3.10 Pendant shall be provided with flourscent up/down/forward/reverse travel push buttons and indicating lamps. Its power supply shall be limited to 24V AC. 14.3.11 The control panel shall be wall mounted type & easily approachable from the floor by a standing man. 14.3.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with ladder shall be provided for each hoist. independent motorised hoist for its handling / 14.3.13 Each inline magnetic separator shall have independent maintenance purpose. Each suspended magnet shall also be provided with a dedicated electric hoist. 14.4 DATA SHEET : MONORAILS AND HOISTS 1.0 GENERAL Functional Requirement : To transfer equipment’s to maintenance area a or outside 1.1 the building. 2.0 2.1.0 2.1.1
2.1.2
DESIGN & CONSTRUCTION REQUIREMENT Hoists Drive More than 2.0 tonne or more than 10.0 m lift or hoists coming out-side out the (i) buildings: Motor driven for both travel & lift. (ii) Other hoists including the hoists for handling takeup pulley and takeup weight: Manual for both travel & lift. Maximum trolley travel speed for electric hoists: 15m/min
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2.1.3 2.1.4 2.1.5 2.1.6
Maximum Hoisting speed for electric hoists: 6 m/min Drive Motors: SQIM, Separate for travel & lift No. of starts for drive motor: 150 starts/hr at 40% CDF Wire Rope (i) Type/Construction: Pre-formed Pre formed type, hemp cored, regular lay 6/36 construction (ii) Breaking Strength: 160-175 160 kgf/sq. mm 2.1.7 Bearing (i) Type: Ball/Roller bearing (ii) Life: 20 years 2.1.8 Brake: Electro Mechanical type with asbestos lining. 2.1.9 Load Hook: Swiveling type forged circular shank section. 2.1.10 Duty: Class –2 2.2.0 Monorail location/layout 2.2.1 Cross section I beam 2.2.2 Distance between C/L C/L of monorail & C.G. of equipment to be lifted Maximum 500 mm 2.2.3 Power Cables Support Festoon type arrangement 2.3.0 Manual Hoists 2.3.1 Maximum manual effort for operation. 30 Kg 15.0 15.1
CHUTES AND HOPPERS GENERAL Chutes & Hoppers, flap gates and shall be furnished integral with coal handling system being supplied. All necessary accessories, electricals etc. shall be provided to ensure proper flow/storage/bifurcation of coal as per system requirements.
15.1.1 CODES AND STANDARDS The design, gn, manufacture, inspection and testing of Chutes & Hoppers shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The chutes, hoppers shall conform to the latest edition editio of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the,contractor of the the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner/RITES shall be final and binding. • IS:4682 :Code of practice for lining of vessels and equipment for chemical processes. • IS:226 : Structural Steel (Standard Quality) • IS:11592 : Code of practice for selection and design of Belt Conveyors. 15.2 DESIGN AND CONSTRUCTION 15.2.1 Chutes, Hoppers 15.2.2 The minimum valley angle of chutes shall be 60 degrees from horizontal. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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15.2.3 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without any accumulation anywhere. 15.2.4 Complete chute work above the drive floor for conveyors provided with ‘In-line ‘In belt magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field. 15.2.5 Direct impact of material on conveyor belt shall be avoided by providing an inclined surface at 60 degrees valley angle at the feeding point to guide the material in the direction of belt travel. Further, chute ute construction below flap gate shaft shall be such that there will not be any accumulation of coal dust between chute and flap gate in that zone. 15.2.6 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL or equivalent material. However, Contractor ntractor to submit test certificates stating composition of material and mechanical properties of these wear resistant steel to the Owner during detail engineering. Long chutes guiding flow from considerable height shall be provided with impact plates wherever ever change in direction of flow takes place. Hinged inspection doors (generously sized) of leak proof construction shall be provided for access/ maintenance purpose, at approachable heights for chutes and flap gates. All chutes should have one inspection door at every floor and for the ones in between the floors (more then 1.5 meter above the operating floor level) suitable access for trouble free maintenance shall be provided. Maximum distance between two inspection doors in a chute shall be 2 mtrs. For sealing s of inspection doors labyrinth type arrangement (with rubber inserted in grooves) to be provided. In addition to positive locking arrangement, mounting bolts, to tighten the door further against rubber shall also be provided. 15.2.7 Bottom side of the chutes on which the coal slides shall be welded to the side plates to form a trough. Bottom sides along with its adjacent sides shall be flanged and made from TISCRAL or equivalent material of 20 mm thickness. The non-striking non striking surface i.e. the covers of o the trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough. Inside welding shall be provided in the corners for permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be joined through bolted flange fl connection to form the chute legs. Adequate care shall be taken to locate the flange joint away from floor level for easy maintenance. Bolted flange joints shall be of dust tight construction and necessary sealing material shall be provided in all the flange connections for adequate sealing. Complete chute work in the region of flap gates shall be fabricated from 20 thk TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) complete chute, work shall be of 20 mm thick TISCRAL TISCRAL or equivalent material. While finalising the chute work inside the building, arrangement for shifting and replacing chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be provided. While fabricating the chute, the constituent constituent plates used shall be in one piece. No welds in between shall be allowed. In the zones of direct impact due to Coal trajectory, wear resistant backing plate with stiffners shall be provided in coal flow chutes. Similar backing plates & stiffening arrangement ement shall also be provided on the chute surfaces having direct coal fall.
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15.2.8 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors with suitable suit access to them. Further, serrated rubber seal shall also be provided at the very inlet of head chute to minimise dust nuisance. 15.2.9 Separate maintenance sealed door shall be provided for access to belt cleaners in head pulley hood impact plates, flap gates for maintenance and inspection doors shall be of hinged with positive locking facility. 15.3.
Skirt Boards
15.3.1 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable ‘Skirt Plates’ of minimum 3.0 meters length shall be provided at each feeding point of conveyor. The width of the Skirt Boards shall be two-third two third the conveyor belt width. width In the beltswhere coal of appreciable lump size (250 mm) is being conveyed, conveyed, the gap between the bottom of the skirt board and the belt shall be made to increase uniformly in the direction of belt travel. The height of the skirt boards shall be sufficient to contain the material volume as it is loaded on the belt and shall not be less than 750 mm. The skirt plates shall be fitted with modular segmented and replaceable rubber skirting pads having facility of adjusting the pressure on the belt conveyor and shall have provision of on line removal for the purpose of easy maintenance. Such segmented rubber pads with its holding holding down adjustment arrangements shall be of proven design. The edges of segmented pads shall be installed at an angle for providing a better seal. All care shall be taken while designing, to combine good sealing with minimum belt wear. 15.4
Flap Gates
15.4.1 The motor operated 2 position flap gates shall be provided in transfer chutes as specified and shall be complete with electrically operated actuators. The gates shall be of robust construction and suitable for trouble free operation. The face of the flap gate shall be made out of 20 mm thick TISCRAL or equivalent material. 15.4.2 The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at rated r load and thrust. The equipment shall be shop tested to prove this requirement. 15.4.3 The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flop gates against the moving weight of coal and/or flap flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. 15.4.4 Lever arm shall be provided between actuator and flap gate shaft for obtaining required thrust. The linkage mechanism proposed shall be indicated in the Bid. 15.4.5 The actuators shall be capable of preventing any over travel. Suitable travel dependent limit switches controlling the travel of the flop gates on either direction shall be furnished. These Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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shall be placed internal to the drive unit and shall be completely dust-proof. dust The limit switches shall be capable of adjustments to vary the total length of travel of the gates. 15.4.6 Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip off thee actuator motor in case of excessive thrust due to jamming of the gates during its travel in either direction. The same shall also be integral to the drive unit and shall be dust proof. 15.4.7 Provision for alternative manual operation shall also be made made using declutchable handwheel. The diameter of handwheel shall be selected considering convenient force to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be provided. 15.4.8 All the two way chutes, one way of which is leading towards the future conveyor, shall be provided with blind flange and flap gate with a provision to mount an actuator in future. 15.4.9 The Contractor shall furnish calculations for selection of actuator for each location for approval of Owner/RITES /RITES. 15.4.10 Suitable stiffening arrangement shall be provided between the two faces of the gate plate. At the end of the travel the total length of edge of the flap gate shall shall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate. 15.4.11 Maximum feasible counterweights shall be provided for better utilisation of system. However, for calculation lation of thrust required, the benefit of counterweight shall not be taken into considerations. 15.4.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for re--greasing shall be provided. 15.4.13 For standardisation purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thrust as calculated for various locations. Flap gate actuator as a whole and individual component component wise shall be completely interchangeable for all locations. 15.4.14 The material of shaft shall be EN-8 EN 8 or equivalent. The diameter of the shaft shall be suitable for motor stalled condition and associated twisting. 15.4.15 Approach/maintenance platforms complete with the chequered plate floor, hand rails, ladders etc. shall be provided for all flap gates. 15.4.16 Shaft & flap gate shall be tightly fitted to each other.
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15.4.17 On both faces of flap gate main plate, 20mm thick TISCRAL liner plate plate or equivalent material shall be provided. 15.5 DATA SHEET : CHUTES AND HOPPERS 1.0 GENERAL 1.1 Coal Parameters As specified elsewhere 2.0 DESIGN & CONSTRUCTION 2.1.0 Chutes & Hoppers MinimumValley Angle: 60 degrees 2.1.1 2.1.2 Material : (a) Chute work Sliding zones & adjacent sides No striking/ Non sliding zones Chute with valley angle 80 degree and above
: 20 mm thk. TISCRAL / equivalent : 10 mm thk MS : All four sides of 20 mm thk. TISCRAL/equivalent material In the zone of magnetic field of ILMS (chute above floor level) : SS-304 304 10 mm thk. In the zone of flap gates : 20 thk TISCRAL/ equivalent material Discharge Hoods over head pulleys : 4 mm thk M.S. with rubber curtain 2.1.3 Size of Chutes : Minimum 1200mm X 1000mm (inside both ways) way 2.1.4 Inspection Doors :Hinged & leak proof construction (min. size 35 x 45 cm) 2.1.5 Chute Construction (a) Corners: One face of removable bolted flange connection (b) Joints Bolted: flange joints of dust tight construction (c) Bolt size: Min. M-16 M (d) Bolts spacing: Not more than 125 mm C/C (e) Fixing Arrangement: Bolts with plain spring washers 2.2.0 Skirt Boards : Min. 3 m for each feeding point 2.2.1 Length 2.2.2 Height : Not less than 750 mm 2.2.3 Width : 2/3 of belt width Side plate : Min. 10 thk TISCRAL/equivalent Top cover : 6 mm thk M.S.
2.3.0 Flap Gate 2.3.1 Type: Linear actuator operated, 2 position 2.3.2 Travel: 60 to 70 deg. (with limit switches on both sides). 2.3.3 Automatic operation (i) Drive: Dust tight motor driven with wit suitable linkages (ii) Minimum Actuator Rating: 2500 kg with 1 m lever arm (iii) No. of Operation / Hr: 15 (with 10 consecutive switchings) (iv) Protection: Travel and Thrust dependent limit Switches. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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2.3.4 Manual Operation (a)
Maximum effort : Convenient for single operator by declutchable hand wheel regardless of electrical power. Minimum Handwheel : Diameter 500 mm
(b) 2.3.5 Flap gate shaft (i) Diameter: minimum 130 mm (ii) Material: EN-8 16.0 16.1
DUST CONTROL AND MISCELLANEOUS SYSTEM GENERAL INTENT OF SPECIFICATION
16.1.1 The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete, Dust Control and Miscellaneous Systems as specified hereinafter required for the Wagon Tippler Package. The Contractor shall refer to the other sections and scheme indicated in the tender drawings to appraise himself of the work and scope of supply of the other Contractors/Owner's and shall coordinate his work with the work of other Contractors. 16. 1.2 Dust Control System The dust control system to be furnished under this specification is required for control of fugitive dust emissions from dust generation points such as transfer points, feeders etc. Dust control is achieved by dust suppression system. system. Contractor shall guarantee and offer dust control system which shall not allow a dust concentration in the ambient air inside the buildings more than acceptable limits as per Owner/RITES Owner approved guidelines or any internationally recognized hygienic Standards/Codes. Standards/Codes. The Capacity of dust control system specified elsewhere is for Contractor’s guidance only. Contractor shall provide adequately sized fool proof dust control systems the performance of which should be guaranteed by the Contractor. However, the he capacity of the offered system shall not be less than the specified values. Further, for computation of design capacity of the pumps, permanent recirculation lines as shown in tender drawings shall also be considered. Water scheme dust suppression shall be provided as indicated in tender drawings. Clarified water shall be used for Service water system, Plain water dust suppression system shall be used for all receipt and discharge points in Transfer. 16.1.3 Miscellaneous Systems Service water system, potable water system, cooling water system & sump pumps shall be provided as specified elsewhere in this specification and as indicated in tender drawings. 16.2 Scope 16.2.1 Plain Water Dust Suppression System Complete with water supply system, piping, spray spray heads, pumps, drive motors with canopy (wherever required), couplings with enclosure, electricals, supporting structures, Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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approach/maintenance platforms, handling for equipment, civil and structural works and necessary accessories shall be provided for WT hopper top & all transfer points, etc. 16.2.2 Sump Pump 4x100% sump pumps alongwith level switches and piping up to nearest Owner's drain (max. up to 50.0 meters from outside the building) shall be provided at all locations wherever natural drainage is not possible. Sump pumps along with drain pits shall be provided at other locations also, if required, during detailed engineering stage. Sealing pumps with valves, piping fittings and other accessories for sealing of sump pumps shall be provided. 16.2.3 Service Water System Service water distribution system complete with water supply system, valves, quick couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy, couplings with enclosure, electricals, including supporting structures, handling for equipment’s, civil and structural works and necessary accessories shall be provided throughout the coal handling plant area in Contractor’s scope. 16.2.4 Pipings, Fittings, Valves and Specialities The material to be supplied for completing the pipe work shall include but not be limited to the following : (1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions, couplings, caps, blank flanges, saddles etc. necessary for making reliable piping system. (2) Gaskets, ring joints, ints, jointing material etc. as required. (3) Instrument tapping connections, stubs. (4) Gate, globe and check valves to start/stop, regulate and to prevent back flow. (5) Duplex Strainers. (6) Anchors, hangers and supports as required including secondary steel embedments etc. (7) Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well as for terminal points. (8) The entire water piping of DS/SW/PW/CW shall be routed/supported on concrete pedestal and conveyor galleries. Whereever the layout does not permit the pipes to be routed over ground, the same shall be buried in conformity to the relevant standards & shall be provided with necessary protective coating as per relevant standards. (9) Painting, anti-corrosive corrosive coatings etc. inside and outside pipes pipes as necessary. (10) Welding electrodes and welding rods. (11) The area around storage tanks strainers, two valves etc. (located out side pump house) shall be paved with drains. 16.3
Terminal Points Owner shall provide supply of water for dust suppression system, service water, potable water at one terminal point as elaborated elsewhere. Beyond the terminal point, the complete pipe work along with associated valves, specialities, instruments, fittings and
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supports, pumps, tanks, etc. as required for the satisfactory operation of dust control, service water & potable water systems shall be furnished by the Contractor. 16.4
Codes and Standards
16.5
The design, manufacture, inspection and testing of Dust Control Control & Miscellaneous Systems shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Dust Control & Miscellaneous Systems shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner/RITES Owner shall be final and binding. • IS:778 : Gun Metal gate, globe & check valves for general purpose. • IS:780 :Sluice valves for water works work purposes (50 to 300 mm) • IS:1239 : Mild Steel tubes & fittings. • IS:2379 :Colour for the identification of pipe line. • IS:2906 :Sluice valves for water work purposes. • IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm) • IS:5312 : Swing check type reflux (non return) valves. • IS:1520 : Horizontal centrifugal pump for clean, cold fresh water. • IS:5120 :Centrifugal pump for clean, cold & fresh water. • ANSI B 31.1:Code for pressure piping. • Hydraulic institute Standards of U.S.A. DESIGN REQUIREMENT Plain Water Dust Suppression
16.5.1 At specified locations dust suppression system shall be provided which comprises spray nozzles discharging plain water in a fine spray to capture air borne dust particles and direct them into the main in coal flow. Water shall be discharged via a pipe work system through spray heads at the dust suppression zones. 16.5.2 Water shall be drawn from the water storage tank by 2x100% electric motor driven pumps and discharged into tank from where 2x100% duty duty electric motor driven pumps shall discharge the water via a pipe network system through spray heads at the dust suppression zones. Solenoid valves shall be provided for open/close control of water line to each spray head. Each spray head shall consist of minimum 4 nos. nozzles. Spray heads shall be provided at coal loading and receipt zone. Pressure at inlet to spray head shall not be less than 2.5 Kg/sq.cm(g). 16.5.3 The dust suppression system over the WT hopper shall have a canopy on which fogging nozzles zzles are fixed at specified distance. Each nozzle header shall be provided with adequate number of spray nozzles spaced at 500 mm interval so that the entire length & width of the wagon tippler hopper are covered by a grid of nozzles. Further, the water spray s shall be of Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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fogging type with a minimum pressure of 2.5 kg/sq.cm(g) at spray nozzle inlet. It should be possible to operate any number of zones simultaneously. The operation of wagon tippler dust suppression system shall be automatic so that the fogging fogging water spray shall get activated only when the tippling is in operation. 16.5.4 Each spray head shall have a provision for installing a pressure gauge whenever required. Further, pressure gauges shall be provided at least at two locations. 16.5.5 Sump Pumps Sump pumps shall be vertical centrifugal type with separate discharge pipe and shall be capable of developing required head at rated capacity for continuous operation. Sump pumps shall be suitable for handling coal slurry & sludge. Head capacity capacity curve of the pump shall be rising type up to the shut off condition. Sump pumps alongwith level switches & piping upto nearest Owner's drain (max upto 50.0 mtrs. from outside the building) shall be provided at all locations wherever natural drainage is not not possible. Further sump pumps alongwith drain pits shall be provided at other locations also, if required, during detailed engineering stage. The capacity of each pump shall not be less than 50 cub. M/hr. Continuous motor rating (name plate rating) at 50 deg. C. for sump pump shall have at least 10% margin above the maximum load demand of the equipment in the entire operating range (including run out condition of pumps in case of parallel operation). The maximum load demand shall include the drive losses in the transmission system. Size of the sump pit shall not be less than 2.0 meters x 2.0 meters x 2.5 meters. One no. of settling pit, of adequate size, before the sump pit shall also be provided so that water without heavy coal particles goes into sump pump pump pit. High and low level switches shall be provided in the sump pump pit. 16.5.6 Service Water (SW) System Service water connections are to be provided in conveyor galleries and tunnels at 50 meter intervals. Adequate number of these connections shall be provided in all transfer houses with minimum one no. at each floor. Each connection shall be provided with one (1) no. 32 NB globe valve and quick coupling. One (1) No. Hose pipe with nozzle shall be provided in each building. Service water distribution distribution system shall be designed considering the water scheme and water requirement indicated in tender drawings. 16.6
CONSTRUCTION REQUIREMENT
16.6.1 Water Supply Pumps 16.6.1.1 Water supply pumps shall be provided as required. 16.6.1.2
The pumps shall be complete with drive motors, baseplate and other accessories. The constructional features of the pump shall be as follows:
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a. Pump casing may be axially or radially split. The casing shall be of robust construction. Casing drain and vent connections shall be provided. b. Impeller shall be made in one piece and securely keyed to the shaft. Locking device shall be provided to prevent its loosening during all conditions of operation. c. Wearing rings shall be of renewable type. Opposed wearing surface shall be of hardened h material and shall have a hardness difference of at least 50 BHN. d. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through bearings and stuffing boxes. The end of the shaft sleeve assembly shall extend through the packing acking gland. Shaft sleeve shall be securely locked or keyed to the shaft to prevent loosening or rotation. Shaft and shaft sleeves shall be machined and assembled for concentric rotation. e. The design of the shaft shall take into consideration the critical speed, which shall be at least 20% away from operating speed. f. Pump bearings shall be of antifriction type. Bearings shall be readily accessible without disturbing the alignment of pump. g. Packed stuffing boxes shall be of sufficient length to prevent leakage leakage along the shaft and shall be complete with all packing and lantern rings required. h. Pumps shall be furnished complete with an approved type of flexible -coupling. i. Couplings guards made of expanded metal and bolted to the base plate shall be furnished. j. The common base plate for pumps and motor shall be in one piece and shall be made of fabricated steel. cum k. Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 cum/hr. 16.6.1.3
The power, head and flow characteristics of each pump shall be suitable for parallel operation. The Power characteristics of the pumps shall be of non overloading type.
16.6.1.4
All rotating parts of the pumps shall be statically and dynamically balanced.
16.6.1.5
The motor shall be rated for continuous continuous operation and confirm to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of pump.
16.6.1.6
Design duty point of pump shall match with the average value of of maximum and minimum flow rates of the pump in the stable operation zone.
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16.6.1.7
Materials of construction of pump components shall be as stated in data-sheet data to this section.
16.6.2
Sump Pumps
16.6.2.1
The column pipe shall serve as a housing for the line shaft and bearing and support for bowl (casing). The line shaft bearing shall be supported from the pump column pipe. Individual sections of column pipe shall be coupled by flanged joints. The flange outside diameter shall not exceed the bowl outside diameter.
16.6.2.2
Casing shall house the impeller and shall be hydraulically designed to minimize radial thrust. Further suitable sealing arrangement shall be provided to prevent the leakage of pumped liquid into the column pipe.
16.6.2.3
The impeller shall be semi open or open (non clogging) as per standard design of the Manufacturer. All rotating parts including the impeller shall be statically and dynamically balanced. Impeller shall be securely fastened to the impeller shaft with keys taper bushings or locknuts and shall be specifically designed to pass large solids or unscreened liquids. The clearances between stationary and moving part shall be such as to allow sustained performance without excessive maintenance.
16.6.2.4
ipe should be terminated above the base plate or mounting channel. The discharge pipe Type of end connection shall be as specified in data sheets. No support shall be provided for the bottom elbow (near pump bowl) to facilitate easy removal of line pump from top without the necessary to go down to the sump for removal of bottom support, if provided. The design of the bunt shaft shall also take into consideration the critical speed of the shall which shall be minimum 20% higher than any operating or run away speed. Individual sections of the shaft shall be interchangeable.
16.6.2.5 16.6.2.6 16.6.2.7
The type of couplings for the line shaft shall be such to prevent loosening during reserve rotation.
16.6.2.8
Line shaft bearings shall be water lubricated. Line shaft bearings bearings shall be spaced not more than 1.5 meters apart. For lubrication purpose clarified water shall be used.
16.6.2.9
For meeting the sealing/lubricating water requirement, Contractor to provide seal water pumps (2x100% capacity).
aft sleeves shall be furnished. The shaft sleeve shall be securely locked to 16.6.2.10 Replaceable shaft shaft to prevent loosening while in operation. 16.6.2.11 Replaceable type wear rings shall be provided for casing and/or impellers wherever applicable. 16.6.2.12 For the following accessories shall be provided for sump pumps Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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(i) Base plates together with foundation bolts and nuts. The base plate shall accommodate the discharge pipe, which is to be terminated above the floor level. (ii) Motor stool. return valves and gate valves valves on pump discharge lines (unless otherwise (iii) Non-return specifically excluded). (iv) Lifting lugs, eye bolts etc. (v) Pre-lubricating lubricating tank with accessories (if necessary). (vi) Sleeves and inserts to be embedded in concrete. (vii) Coupling guard, if necessary 16.6.2.13 The pump shaft shall be connected to motor shaft by a heavy duty rigid/flexible coupling or the pump shall be V-belt V driven. 16.6.3 PIPING, FITTINGS, VALVES AND SPECIALTIES 16.6.3.1 Piping & Fittings (a) Material of construction of piping and fittings shall not be inferior to those given in data sheet of this section. (b) All piping shall be capable of withstanding the maximum pressure in the corresponding line at the relevant temperature. (c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding and pipe work of size 50 mm NB and below by socket welding/screwed connections. Joints at valves or specialities shall be flanged for sizes 65 mm NB or large and screwed for sizes 50 mm NB and below. All galvanized piping shall be joined by screwed connections. connections. Minimum pipe diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall be 32 NB. (d) End preparation for butt welding shall be done by machine/flame cutting. Socket weld and preparation shall be saw/machine cut. (e) Hangers and supports ports shall be capable of carrying the sum of all concurrently acting loads. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. All guides, anchors, braces, dampers, expansion joints and structural steel to be attached to the building/structure, trenches etc. shall be provided. The type of hangers and components for all piping shall be selected and approval obtained from the Owner/RITES. Owner (f) All piping shall be routed on ground on concrete pedestals and at road crossings, these shall be laid through hume pipes. 16.6.3.2 Valves and Specialties (a) Valves & Specialties shall be used to start, stop or regulate the flow. All valves/specialities below 50 mm size (for isolation purpose) in service water/dust suppression/potable water lines should be plug type of proven make. (b) All valves shall be suitable for most stringent service conditions i.e. flow, temperature and pressure under which they may be required to operate.
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(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50 NB and Globe valves shall be used for regulating the flow. (d) Valves shall be provided with back seating bush to facilitate gland renewal during full open operation. (e) All gate and globe valves of size 65 NB and large shall be bolted bonnet, outside screw, rising type with flanged ends. Valves of size 50 NB and smaller shall be with screwed ends. (f)
Valves shall be provided with the following as necessary: i. Hand wheel ii. Position indicator pass valve and spur gear reduction reductio unit for larger valves. iii. By-pass iv. Draining arrangement.
(g) Material of construction of valves shall not be inferior to those given in data sheet of this section. (h) Globe valves shall be provided with contoured plug to have well controllability. (i) (j)
Non-return valves shall be swing check type. These valves will have a permanent ‘arrow’ inscription on its body to indicate direction of motion of the fluid. All valves shall be provided with hand wheel, chain operated, extension spindle and floor stand wherever required so that they can be easily operated either at a lower or higher elevation as the case may be.
(k) Strainer shall be of duplex type designed with 3 way valves so that one filter can be cleaned while the other is in operation. Suitable vent and drain valves shall also be provided. Screen opening area shall be at least four times the pipe cross sectional area. Pressure drop in clean conditions shall not exceed 1.5 MWC at full flow. (l)
Bib cocks provided for potable water system shall be made of stainless steel
16.6.4 Special cleaning, protection and painting 16.6.4.1 Piping & Fittings (a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. p (b) For over ground exposed steel pipes, one shop and one site coat of red oxide zinc phosphate and two coats of synthetic enamel finishing paints unless specified otherwise shall be applied. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. duty bitumastic paint shall be applied on (c) For steel buried pipeline, three (3) coats of heavy duty the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty bitumastic paint. 16.7
DATA SHEET : DUST CONTROL & MISCELLANEOUS SYSTEM 1.0 GENERAL 1.1 1.2
Dust Control: Plain water dust suppression Miscellaneous systems: Service water system, Potable water system, Cooling water system & Sump pumps.
2.0
DESIGN REQUIREMENT
2.1 2.1.1 2.1.2 2.1.3
Dust Suppression ration: Water sprayed through nozzles. Operation: Pumps: 2x100% for water Spray Head (i) Minimum No. of nozzles per spray head: 4 (Four) (ii) Pressure at inlet: Minimum 2.5 kg/sq. cm
2.2.0 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5
Plain Water Dust Suppression Pumps: 2x100% electric motor driven Minimum Pressure at inlet of spray nozzles: 2.5 kg/sq. cm Nozzle spacing on WT Top: 500 mm Nozzles: Fogging type Flow from each nozzle: 2.0 Lpm
2.3.0
Sumps Pumps (i) Type: 2x100% electric motor driven (ii) Capacity: 50 cub.m/hr minimum with 10% margin (iii) Head: 20% margin on computed head
2.3.1
Drain Pits: Minimum 2x2x2.5 mts. and 1 No. settling pit for slurry & high/low level switches in drain pit.
2.3.2
Piping: To nearest plant drain
2.4.0 2.4.1
ice Water System Service Water connections (a) Conveyor Galleries and tunnels: every 50 m (b) Transfer points: Min. 1 no. at every floor
2.4.2
Connection details: 1 No. 32 NB globe valve & quick coupling
2.4.3
Hose pipes with hose reel: One in each building of 25 mtr. Length with nozzle
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3.0
CONSTRUCTION REQUIREMENTS
3.1
Water Supply Pumps for DS/SW/PW/CW
3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9
Casing Axial or radially split with drain & vent connection Impeller One piece, keyed to shaft along with locking device Shaft Critical speed atleast 20% away from operating speed Shaft sleeves at bearings & stuffing boxes. Bearings Antifriction type Wearing rings Renewable type (preferable) Pump speed Below 1500 rpm for capacity more than 10 cub. m/hr. Head flow characteristics Suitable for parallel operation. Materials (a) Casing: Cast Iron to IS:210, FG 260 (b) Impeller: Bronze conforming to Gr.I of IS:318 (c) Impeller Wearing ring: Bronze conforming to Gr.I of IS:318 (d) Casing Wearing ring: Bronze conforming to Gr.I of IS:318 (e) Shaft: Medium carbon steel (f) Shaft sleeve: Stainless steel conforming to AISI-416 AISI hardened. (g) Gland packing: Impregnated Teflon
3.2.0 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6
Sump Pumps Type: Vertical, centrifugal, single stage, stage, semi open or open (non clogging) type impeller. Duty: Intermittent. However, to be designed for contineous operation. Fluid to be Pumped: Sludge/Coal slurry Suction Condition: Submerged Pump speed (maximum): 1000 RPM Type of coupling between pump and motor: Directly driven through flexible or rigid coupling/V-Belt 3.2.7 Location of pump thrust bearing: In motor stool 3.2.8 Materials (a) Casing: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.) (b) Impeller: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.) (c) Impeller: Shaft Stainless steel (d) Line Shaft: EN-8 8 to BS; 970 (e) Column pipe and discharge pipe: Fabricated steel to IS: 226 (min. 6mm thick). (f) Shaft sleeve: Hardened stainless steel to 400 BHN (g) Base Plate: Steel to IS: 226 up to 20mm thickness and IS: 2062 over 20mm thickness. 3.2.9 Accessories Provided with the Pump i. Lubrication and sealing water system: Yes ii. Common base plate for Pumps and Motor and Motor stool: Yes iii. Anchor Bolts, nuts, sleeves and inserts (which will be embedded in concrete): Yes iv. Coupling, guards lifting lug, eye bolt, positioning Dove: Yes
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3.3.0 Pipings & Fittings 3.3.1 Joints (i) Pipe to pipe Pipe size < 50 NB: Socket welding/screwed Butt Pipe size > 65 NB: welding (ii) Pipe to valves 0 NB: Screwed Pipe size ≤ 50 Pipe size ≥ 65 NB: Flanged 3.3.2 3.3.3
Isolation of flow: Plug / Gate / Sluice valves Regulation of flow: Globe Valve
3.3.4 Valves Size > 65 NB: Bolted bonnet outside screw rising type. i. ii. Size < 50 NB: Union bonnet with screwed ends for Globe valves & screwed ends for plug valves. 3.3.5 Materials for Pipework For sizes 200 NB and Larger: ERW carbon steel pipes to API-5LGr.B API minimum thick 6.35 mm or plate fabricated and welded pipes to IS:3589, Class-2. Class (b) For sizes 150 NB to 65 NB: ERW carbon steel black pipes to IS:1239 (Part-I, (Part Heavy Class). (Part Heavy (c) For sizes upto 50 NB: ERW carbon steel galvanized pipes to IS:1239 (Part-I) class. (a)
3.3.6 (a)
(b)
(c)
(d)
Materials for Valves & Specialities Cast Iron Valves: (65 NB & above) i. Body and bonnet: Cast Iron to IS:210, Gr.FG-200 ii. Disc for nonnon return: Cast Iron to IS:210, Gr.FG-200 200 valves iii. Seating surfaces and rings: 13% chromium steel iv. Hinge pin for non return valves: Stainless steel type AISIAISI-316 v. Stem for gate and globe valves: 13% chromium steel vi. Back seat bush: 13% chromium steel Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2) (i) Body: Gun metal to IS:318, Gr-2. Gr (ii) Trim: Gun metal to IS:318, Gr-2. Gr Duplex Strainer (i) Body: MS fabricated (ii) Strainer: Stainless steel type element AISI-316 Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and syphon) (i) Dial size : 150 mm (ii) Accuracy : (+/-) 1% of range span
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(iii) (iv) (v) (vi)
(e)
(f)
Bourdon Block Movement
: AISI 316 SS : AISI 316 SS : AISI 316 SS Case and Bezel : Die cast Alum. Weather proof case stove enameled block with screwed type inner bezel of ABS plastic and glycerin filled. (vii) No. of contacts : 2 NO + 2 NC (viii) Type of contact : Adjustable throughout the range. (ix) Degree of protection : IP. 65 Solenoid valve (to be provided with isolating valve) (i) Type : 2/2 way Diaphragm type pilot operated (ii) Diaphragm : molded synthetic rubber (iii) Body : Forged brass / SS (iv) Pressure : 0.5 to 20 kg/cm2 (v) Protection : Class IP 65 Flow Switch (to be provided with isolating valves) (i) Body : Forged steel (ii) Extension Rod/wire : SS-304 (iii) Sleeve and Sleeve pipe: SS-304 SS (iv) Cover : Die cast aluminum (v) Max. working pressure : 10 kg/sq.cm (vi) Repeatability : ± 0.5% (vii)No. of contacts : 2 NO + 2 NC (viii)Type of contact : Adjustable throughout the range. (ix) Protection : class IP – 65
(g)
Level Switch (i) Type : Displacer operated magnetic type (ii) Displacer: SS – 316 (iii) Wire rope: SS – 316 (iii) Spring Housing Spring and sleeve pipe: SS – 316 (iv) Cover: Cast Aluminum (v) No. of Contacts: 2 NO + 2 NC (vi)Type of Contact: Adjustable throughout the range. (viii)Protection: class IP – 65 (h) Level gauges (i) Type: Float type mechanical gauge with wit arrow scale (ii) Accuracy: (+/--) 1% of full scale range (iii) Material of construction (a) Float & Guide wire: 316 SS (b) Elbows: Suitable grade of SS (c) Housing: Mild Steel (d) Cable fastener: SS 304 (i) Nozzles
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(i) Type: Fogging, non-clogging non type (ii) Material: Stainless Steel (iii) Nozzle housing : To ensure protection of nozzle against damage. (j) Y Strainer (a) Body: SS 304 (b) Plug: SS 304 (c) Filter Element: SS 316, 60 mesh 17.0
VENTILATION SYSTEMS
17.1 GENERAL 17.1.1 INTENT OF SPECIFICATION The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete Ventilation & air conditioning systems as specified hereinafter for the smooth and trouble free operation of plant & equipment of Wagon tippler package. 17.1.1.1 The Contractor shall refer to the other sections enclosed to appraise himself of the work and scope of supply of the other Contractors and shall coordinate his work with the work of other Contractors. 17.2
GENERAL DESCRIPTION
17.2.1 Mechanical Ventilation system The air quantity for mechanical ventilation system shall be estimated based on equipment and solar heat loads and the temperature rise inside the building. Necessary air filters shall be provided ided to supply only clean air into building. Exhaust air shall be discharged at a suitable height above building. Exhaust fans shall be provided for Toilets, Battery rooms. All underground structure shall be provided with supply air as well as exhaust air fans. 17.2.2 Pressurised Ventilation System The pressurised ventilation system having adequate nos. of supply and exhaust air fans with washable metallic pre filters, HDPE fine filters, and exhaust fans with self closing flaps, ducting along with 3 phase phase AC motor drives, electricals, supporting structures, access / maintenance platforms shall be provided in all MCC/switchgear room areas of coal handling plant to be furnished under this specification. The pressurized ventilation system shall be designed considering onsidering 20 air changes per hour to maintain these areas pressurized slightly above atmospheric pressure to prevent ingress of dust from outside. 17.2.3 Air Conditioning System Air conditioning system shall be furnished for control room area of Wagon tippler control building, it shall be designed considering the equipment heat loads, solar heat loads, heat Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and relative humidity within the air conditioned areas. 17.3
SCOPE
17.3.1 Mechanical Ventilation System The ventilation system generally consisting of adequate number of supply and exhaust air fans, air filters, ducting along with 3 phase AC motor drives, electricals, supporting structures, approach/maintenance platforms, civil and structural works and necessary accessories shall be furnished for ventilating the WT hopper, underground portion of transfer points, underground conveyor tunnels tunnels and pent houses. Exhaust fans shall be provided for Toilets & Battery rooms. 17.3.2 Pressurised Mechanical Ventilation System The ventilation system generally consisting of adequate number of supply and exhaust fans, metallic pre filters, HDPE fine filters, filters, ducting along with 3 phase AC motor drives, electricals, supporting structures, approach / maintenance platforms, necessary shed, civil & structural works and necessary accessories shall be furnished for all MCC/switchgear rooms. 17.3.3 Air Conditioning ioning System 17.3.4 2x100% capacity air conditioning units shall be provided for Wagon Tippler Control Room. 17.3.5 Supply and return air distribution ducting complete with insulation, of resin bonded mineral wool equivalent of density at least 24 Kg/m³ Kg/m³ and thermal conductivity of max. 0.49 mw/cm°C conforming to IS:8183 including supporting structures, approach/ maintenance platforms, civil and structural works and necessary accessories shall be provided. provided 17.3.6 Air cooled PAC shall be provided. 17.3.7 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear surrounding. 17.4
Codes & Standards The design, manufacture, inspection and testing of Ventilation & A/C System shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Ventilation & A/C System shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, ion, the decision of the Owner/RITES Owner shall be final and binding. •
IS:3588 : Specification for electrical axial flow fans.
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• • • • • • • • • •
IS:2312 :Propeller type AC Ventilation fans IS:3963 :Specification for roof-extractor roof units IS:4894 :Centrifugal Fans IS:655 :Specification ation for Metal Air Duct ARI:210 :Standard for Unitary air conditioning equipment. ARI:270 :Standard for application, installation and servicing of unitary equipment. IS:8183 :Specification for bonded mineral wool. IS:661 :Thermal insulation for cold surfaces. surfa IS:4671:Expanded polystyrene for thermal insulation purpose. IS:8148 :Packaged Air conditioners.
17.5 DESIGN REQUIREMENT 17.5.1 Roof Ventilators & Accessories 17.5.2 Roof ventilators & accessories shall be provided as required. Impeller shall be axial flow type. 17.5.3 Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in stable operation zone. 17.5.4 The speed of the roof ventilators shall not exceed 960 rpm for ventilators with impeller diameter above 450 mm & 1440 rpm for ventilators with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed. 17.5.5 Motor shall be totally enclosed type suitable for vertical mounting. mounting. Motors shall comply with the companion electrical specifications. 17.5.6 Axial Fans 17.5.7 Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in the stable operation zone. The speed of the fan shall not exceed 960 rpm for fan with impeller diameter above 450 mm and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed. low type single piece. 17.5.8 Impellers shall be axial flow 17.5.9 Centrifugal Fans 17.5.10 The fan units shall be centrifugal type with radial bladed impeller. For design purpose out door ambient temperature shall be taken as 50 deg.C. 17.5.11 Fans shall be manufactured vibration free in operation and shall be designed to limit noise level within limits specified in Data Sheet. 17.5.12 The motor shall be rated for continuous operation and conform to companion electrical specification. However, motor rating shall not be less than the max. m power demand throughout the entire range of operation of fan. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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17.5.13 All fan mountings shall have adequate arrangement for vibration isolation. non working fan shall be prevented by dampers. The dampers 17.5.14 The reverse flow through non-working shall be made out of 18 SWG MS sheets. 17.5.15 Design duty point of the fans shall match with the average value of maximum and minimum flow rate of the fan in the stable operation oper zone. 17.5.16 Filters 17.5.16.1 Metallic Filters Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be 2 m/sec. 17.5.16.2 HDPE Filters HDPE filters should have an efficiency of 90% down to 5 microns. Velocity Velocity across the filter shall be limited to 2.5 m/sec. 17.5.17 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99.9% down to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm w.c. Conditioning Unit 17.5.18 Packaged Air-Conditioning PAC units shall be provided as required. 17.5.19 PAC units shall be factory tested and assembled self contained units complete with refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units wherever required shall be insulated with expanded polyethylene conforming to IS:4671. 17.5.20 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled condenser (outdoor air) section. Heavy gauge steel cabinet factory finished with two coats of epoxy paint of approved colour, shall be used to house components of PAC. 17.5.21 The evaporator and condenser coils shall be arranged for direct expansion cooling and shall be formed of aluminum fins mechanically bonded to seamless copper tubes and electrically tinned. The inter-connecting connecting refrigerant circuits shall comprise of multiple cylinder hermetic compressor(s) and motor(s) with all necessary isolation valves, suction gas controlled thermal expansion valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries. The condenser coils shall be air cooled by propeller type fans complete with safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pick-up pick from solar sources.
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17.5.22 Condenser capacity control shall be provided by means of variable speed fans and ‘head pressure’ sensing. 17.5.23 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by individual motor(s) and suitable for the external static pressure. The fan assembly shall be isolated from the casing by anti-vibration anti vibration mounts. The fan/motor drive shall be capable of capacity adjustment by pulley changes within +15% of design duty. 17.5.24 High efficiency filters shall be provided provided in the main supply air duct and in the fresh air connection to return air duct. 17.6
Construction Requirements
17.6.1 General construction details of various equipment under Contractor’s scope shall be as elaborated in subsequent clauses below. 17.6.2 Roof Ventilators and accessories Roof ventilators and accessories shall be provided as required. 17.6.3 Impeller shall be axial flow type, cast in one piece finished all over and carefully dynamically balanced after final assembly. All impellers shall consist of high efficiency aerofoil blades. Impellers shall be mounted directly on the motor shaft. 17.6.4 Casing shall be of heavy gauge construction and shall be properly reinforced for rigidity. Access door with suitable locking arrangement arrang shall be provided. 17.6.5 Hood shall be of hinged type providing easy access to motor and impeller. It will also protect them from rain and any other contingencies. Weather-proof Weather proof lockable type disconnect switch shall be provided such that the hoods can be opened only when the disconnect switch is in ‘OFF’ positions. On larger sizes of roof ventilators, hoods shall be of split construction. 15 mm mesh galvanised bird screen shall be provided. The hoods will have low pressure drop across it. 17.6.6 Suitable uitable arrangement shall be provided for mounting the roof ventilators such that ingress of rainwater into the building will be avoided completely. 17.6.7 Axial Flow Fans Axial flow fans shall be provided as required. 17.6.8 Impellers shall be axial flow flow type and single piece cast aluminum with aerofoil blades construction. It shall be finished all over and balanced dynamically. Impeller shall be mounted directly on the motor shaft. 17.6.9
Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall be provided with suitable supports. Access door shall be provided in the casing for easy access to motor and impeller. Suitable arrangement for mounting of motor shall be provided.
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17.6.10 Rain protection cowls will be designed designed to suit wall exhausters/supply fans for protecting fans/motors from rain. It will be provided with bird screen. 17.6.11 Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or M.S. otally enclosed type complying with the companion electrical 17.6.12 Motor shall be of totally specification. Suitable rain/sun shade for motors shall also be provided. 17.6.13 Centrifugal Fan Centrifugal fans shall be provided as required. 17.6.14 The casing shall be of welded construction fabricated with heavy gauge material. It shall be rigidly reinforced and supported by structural angles. The seams shall be permanently sealed airtight. Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be provided wherever required. 17.6.15 The impeller shall have die formed curved blades fabricated out of MS heavy gauge welded to the rim and back plate to have a non overloading characteristics of the fan. Rim shall be spun to have ve a smooth contour. If required intermediate stiffening rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically balanced. Fan shaft shall be of EN-8 equivalent. 17.6.16 The bearings shall be self-aligning self heavy-duty duty ball or roller bearings. They shall be adequately supported. They shall be easily accessible and lubricated properly from outside. 17.6.17 Filters 17.6.18 Metallic Filters allic cleanable filters shall consist of V-fold V fold galvanised wire mesh inter spaced with a flat Metallic layer of galvanised wire mesh. The density of the filter medium shall increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to eliminate the danger of abrasion during handling. Filter medium shall be supported on either side by galvanised expanded metal casing. Filter frame shall be constructed from galvanised sheet of thickness not less than 18 gauge. 17.6.19 HDPE Filters all be provided as required. This shall be constructed of HDPE fabric with HDPE filters shall continuous water spraying on it from a header for keeping it clean. 17.6.20 High efficiency filter (for A/C purpose)
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The media of the filter shall be made from either special synthetic non-woven non bond fiber design or made from micro fiber glass media. It shall be supported with GI wire mesh or aluminum mesh and shall be housed in an aluminum sheet frame. It shall be of washable type several times. 17.6.21 Package A/C Unit .22 A separate cubicle shall be provided within the overall casing to house the thermostatic 17.6.22 controls, which shall be electric/electronic solid state, prewired and tested. The refrigerant system shall be protected by pressure limiting devices, electric and thermal overloads and unloading facilities to provide the required control range tolerances. A low voltage room thermostat shall be provided for wall mounting. The casing shall be fitted with all necessary coil drains and service connections/ entries. 17.. 6.23 PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The units shall be fully packaged and incorporate integral room air sensing control thermostats and manufacturers work fitted safety interlocks. All controls shall be prewired prewir to unit mounted control/power terminal boxes. 17.6.24 Ventilation and Air Conditioning system ducting 17.6.25 All GI sheet metal ductwork required for ventilation and air conditioning system shall be furnished by the supplier. All ducts and plenums unless otherwise noted shall be constructed out of standard quality galvanised steel sheet. All sheet metal ducts shall be fabricated and installed in conformity to the requirements of IS:655. Steel supports for the ductwork shall be furnished as required. The thickness of ducting steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be 1.25 mm. The flexible connection between fan and ducting shall be on Teflon impregnated canvas. The zinc coating on GI sheet shall be 275 gm/cm2. 17.7
DATA SHEET : VENTILATION SYSTEM 1.0 GENERAL 1.1.0 1.1.1
Mech. Ventilation System: To provide ventilation using fans for specified areas. No. of air changes per hour (a) For overground building: Not less than 10 supply air changes & 7 Exhaust air changes (b) For underground areas: Not less than 15 supply air changes & 7 Exhaust air changes
1.1.2 Equipment (1) Underground tunnel: Centrifugal fans/Axial Fans (2) All other places: Axial fans, roof ventilators 1.2.0 Pressurised ventilation ventilation system: To provide clean air to all MCC / Switchgear buildings 1.2.1 No. of air changes per hour: Not less than 20 Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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1.2.2 Equipment: Centrifugal fans/Axial Fans and exhaust air fan conditioning system As specified 1.3.0 Air-conditioning 1.3.1 Temperature to be maintained : 24 ± 1 deg. C 1.3.2 Humidity to be maintained : 50 ± 5% relative humidity 1.3.3 Fresh Air intake : More than 1.5 air changes per hour. 1.3.4 Equipment: 2 x 100 % roof mounted package AC units along with ducting etc. and window AC 1.4.0 Outside Ambient Conditions (i) Summer: As per weather data given in project synopsis. (ii) Monsoon: - Do – (iii) Winter: - Do 2.0.0 DESIGN & CONSTRUCTION 2.1.0 Roof Ventilators 2.1.1 Capacity: 10% more of actual requirement 2.1.2 Head: 20% more of actual requirement 2.1.3 Speed (a) Impeller: dia above 450 mm Max. 960 rpm (b) Impeller: dia less than or equal to 450 mm Max. 1440 rpm (c) Critical speed: 25% above operating speed. 2.2.0 Axial Fans 2.2.1 Capacity: 10% more of actual requirement 2.2.2 Head: 20% more of actual requirement 2.2.3 Speed (a) Impeller: dia above 450 mm Max. 960 rpm (b) Impeller: dia less than or equal to 450 mm Max. 1440 rpm (c) Critical speed: 25% above operating speed. 2.3.0 Centrifugal Fans 2.3.1 Capacity: 10% more of actual actu requirement 2.3.2 Head: 20% more than actual requirement 2.3.3 Speed: Max. 1500 rpm 2.3.4 Outdoor temperature: 50 deg.C. 2.3.5 Rating: Continuous Conditioning Unit 2.4.0 Packaged Air-Conditioning 2.4.1 Type: Roof top mounting 2.4.2 Service/application: Continuous, round the clock. 2.4.3 Capacity (i) TR: Suitable (ii) CFM: Suitable 2.4.4 Type of compressor: Multiple cylinder hermetic compressor. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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2.4.5 Condenser: Air cooled type 2.4.6 Fan: Forward curved centrifugal fan 2.4.7 Filter: High efficiency filter 2.4.8 Cooling Coil (a) Type: Direct Expansion (b) Material: Copper (c) Fins: Aluminum mechanically bonded. 2.4.9 Refrigerant: Piping Copper 2.4.10 Insulation for PAC parts: Expanded polyethylene of density at least 15 kg/cub.m. 2.5.0 Filters 2.5.1. Metallic Filters (1) Max. air velocity: 2m/sec. 2.5.2 HDPE filters (1) Efficiency: 90% down to 5 microns (2) Max. velocity: 2.5 m/sec. (3) Testing: As per BS 2831 / Sqv. 2.5.3 High Efficiency Filter (1) Efficiency: 99.9% down to 5 microns. (2) Pr. drop across: 10 mm W.C. (3) Testing: As per BS 2831 / Sqv. 2.6.0 Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183 2.6.1 Density: 24 kg/cub.m 2.6.2 Thermal conductivity: 0.49 mw/cm deg.C 18.0 DESIGN OF CONVEYOR GALLERIES AND JUNCTION HOUSES 18.1 Design Considerations 11592 a) The general parameters for conveyor galleries shall conform to the provision of IS : 115921985 unless specified otherwise in Technical Specifications. The structures shall be designed so as to meet functional requirements requirements and shall provide space for operation, maintenance and removal of machinery and give the workers good and safe environment. b) Gallery floors shall be of chequered plates supported on steel beams. mm along the walkways if the gallery c) Steps shall be provided with (rise not exceeding 130 mm slope exceeds 12°.. In case the slope of gallery is between 6° 6 to 12°,, suitable ribs (without any sharp edges) shall be provided on floor at 250 to 300 mm intervals. d) Roof and side walls of conveyor galleries shall be covered with Aluminium industrial troughed sheets.. with a provision of gap of 300 mm below roof and 150 mm from top of floor level on the side wall for ventilation. inside conveyor gallery shall be made through side walls e) Adequate provision for natural light inside by providing translucent sheets (FRP sheets as per IS: 12866-1989). 12866 1989). Every sixth sheet on side wall shall be FRP sheet and shall be staggered on opposite wall. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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b 1:5 (1 vertical, 5 Horizontal). f) Roof slopes of conveyor galleries shall be g) The level of underside of the base plate of gallery supporting trestles shall be 300 mm above the average ground level of the surrounding area. platf stairways, h) Protective hand railing shall be provided along gallery walkways, open platform, landings, edges of walkways when the gallery is not enclosed, and around erection openings, if any, to ensure safety of operating personnel. i) Conveyor galleries longer than 150 m shall be provided with expansion joints with twin trestles/supports. pports. Each expansion block shall have fixed support/rigid trestle with adequate arrangement (provision of top chord and bottom chord bracing to gallery girder etc.) for transferring the transverse and longitudinal forces to the foundation. rs near junction house shall be preferably supported on trestle located as close j) Gallery girders to the junction house as possible, with part of gallery girder between junction house and trestle cantilevered from the trestle. Supporting gallery girders on junction house shall s be generally avoided. k) The underside of the belt conveyor shall be fully covered with 3 mm sheet in case of conveyors located within the boundaries of the plant area. including the gallery crossing the roads / railway lines / areas of public gatherings. gathering l) When conveyor gallery crosses above or below H.T cables, a minimum clear distance of 1.0 m between the structural elements/cladding and HT cables shall be maintained. m) When the conveyor bridge passes over plant roads, clearance between the road surface and the lowest points of the bridges shall not be less than 8.0 m or the height needed for the passage of the largest individual components of the plant equipment, whichever is the larger. n) The junction house shall be designed to suit the functional requirement. Number of floors, height of building etc. shall be decided accordingly. o) In general the junction house shall be designed as framed structures on shorter span side and vertically braced on longer side to achieve stability. ouses shall be of RCC slab / Chequered plate supported on steel beams, p) Floor of junction houses unless required otherwise from technological suitable lugs. q) Roof and side covering of junction houses shall be with Aluminium industrial troughed sheets as specified. Roof slope shall be 1: 5 ( 1 Vertical : 5 Horizontal).
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r) Suitable access staircase with safety hand railing shall be provided to all floors of junction houses. s) Wall sheeting shall generally start from the lowest working floor and extend up to roof level with louvers at each h floor level to ensure adequate natural ventilation. t) Monorails for maintenance hoists shall be provided for maintenance and repair of various equipments located on the floors. 18.2 Components of structures a) Gallery Trusses and Roof Gallery truss shall be of latticed type construction. The trusses shall be adequately braced at top and bottom chord level to transfer the horizontal wind forces to end portals. b) Stringer Beam These beams shall be suitably spaced to support the conveyor stringer supports and shall transfer load to gallery. Walkways on either side of the conveyor shall also be supported on these stringer beams. c) Supporting Trestles Intermediate trestles shall be two legged and shall deliver loads from gallery trusses to the foundations. In addition, four legged trestles shall be provided which will act as fixed support to transmit all longitudinal forces between expansion block, in addition to other forces. d) Junction Houses layout as well as equipment i) Floors - Floor beam layout shall be arranged to suit equipment layout anchoring system. ii) Columns - In addition to loads from floor and roof, columns shall be designed to transmit horizontal load due to belt tension/snapping of belts to the foundation. e) Belt Tensioning Device belt tensioning device which may be Suitable structures shall be provided to accommodate belt-tensioning located either under the conveyor gallery or in the junction house itself. f) (i) (ii)
Wall Structures Wall runners with necessary sag rods shall be provided to support wall sheeting in conveyor galleries and junction houses. Walls shall be provided with louvers and translucent sheeting at appropriate levels, to provide natural ventilation and lighting.
g) Access stairs, walkways, platforms, ladders, hand railing etc. Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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(i) Wherever possible, access shall be provided by means of stairs. (ii) All walkways and stairs leading to working platforms shall have minimum 800 mm width of walkways/flight of stair. (iii) All other walkways and stairs leading to areas for maintenance purpose, or due to restriction iction of space, shall have a minimum width of 800 mm of walkway/flight of stair, unless required otherwise. (iv) Staircases shall be generally designed with slope of approximate 37.5° 37.5 with the horizontal. (In no case the slope shall exceed 40 ° with the horizontal). horizo Intermediate landings shall be provided wherever required such that vertical rise of each flight does not exceed 3000mm. Risers in one flight shall be equally spaced. (v) Walkway floors and stair treads shall be designed with chequered plate (or non-slip non type plates). Ribbed floor/treads may be provided wherever the possibility of accumulation of dust exists, taking care that such provisions do not crate a nuisance to the operating personnel on the shop floor. (vi) Rise of treads in staircases shall not exceed excee 200 mm. (vii) A minimum headroom of 2200 mm shall be provided over operating platforms, visitor's galleries, or other areas with possibility of public gathering. In all other platforms, walkways and stairs, minimum headroom of 2000 mm shall be provided. Only in i special cases, local headroom of 1800 mm may be allowed (i.e. at intersection with structural members etc.). (viii) Cat ladders shall be provided for access, wherever provision of staircase is impractical due to limitations of space, or the access is required very very infrequently. (ix) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be provided. Intermediate landing shall be provided to cat ladders such that vertical height of single rise does not exceed 8.0 m. (x) Cat ladders shall be designed with following follo provisions: i. Width of rung = 500 mm ii. Minimum rise of rung = 250 mm; Maximum rise of rung = 300 mm iii. Minimum clearance from rung of ladder to back of cage (in case of caged ladders) = 700 mm iv. Minimum clearance from the centre of cage all round = 350 mm v. Slope of cat--ladders: I. For normal cat-ladders, cat ladders, slope shall be within the range of 75°-90° 75 with the horizontal. type ladders (i.e cat-ladders cat ladders with short side handrails) the slope shall be II. For ship-type within the range of 65°-75° 65 with the horizontal. (xi) All walkways, platforms and stairs shall be provided with safety handrails. All handrails shall be constructed with steel tubes / angles for posts, top and middle rail and plates/sheets for toe plates. In case of stairs, the toe guards need not be provided. (xii) The he vertical height of hand-railings hand railings on walkways and stairs shall be minimum 1000 mm above floor level. railing along edge of roof and gutters shall have a minimum height of 600 mm (xiii) Hand-railing over top edge of gutters/sheets. In such hand railings toe guards need not be provided. (Only top handrail and midrail shall be provided). Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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18.3
ADDITIONAL DESIGN CRITERIA a)
Design of steel structures shall be done in accordance with IS:800-1984. IS:800 1984.
b)
In absence of specified dynamic factor to be considered for the load from the belt conveyor, a dynamic factor of not less than 1.3 shall be considered for the design of floor beams and gallery girders. Gallery trusses and stringers as well as floor beams beams of junction house shall be checked for obviating occurrence of resonance and shall be designed such that the ratio of applied frequency to natural frequency shall not lie within the range 0.7 to 1.5.
c)
d)
As far as possible gallery structure shall be made made independent of junction houses. A trestle shall be planned close to the junction house to avoid gallery span resting on the junction house.
e)
The contractor after the award of work shall submit design criteria to owner / consultant for approval before befo submission of design drawings.
f)
The design drawings shall be submitted in complete for a unit along with design calculations both in hard copy and soft copy. Design shall be done using STAAD.
g) The effective ratio of utility of all main sections shall be limited to 0.85 h) Structural schematic general arrangement with plans at various levels, elevations along each row and axes, sections, considered loads and load diagrams with location etc. and Structural design drawings with BOQ and Table of members members containing design forces shall be submitted for Owner’s/Consultant’s approval. However the approval shall be limited to checking of overall dimensions, general stability of system, effective load transfer and deflection limits etc. The approval shall not relieve the contractor of his responsibility of correctness in design, adequacy of connections, accuracy etc. i) Submission of Stability certificate for all the steel structures is under the scope of the contractor. 18.4
Description of loads and loading codes a) b) c) d) e)
Unless specified otherwise hereinafter, all the live loads shall be considered in accordance with IS: 875 (Part-2) (Part -1987. Wind loads shall be considered in accordance with IS: 875 (Part-3)-1987. (Part 1987. Seismic loads shall be considered in accordance accordance with IS:1893(part1)-2002 IS:1893(part1) and 1893(part 4)-2005 Live loads from conveyor on the gallery floor shall be as per conveyor suppliers load data. While designing the fixed support/rigid trestles in an expansion block of conveyor gallery the following loads (in addition to wind load) shall be considered.
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(i) Forces due to difference in frictional resistance of top and return idle rollers of conveyor. (ii) Forces due to inertia of rollers at the time of starting of conveyor belt. (iii) Break down load caused by snapping of belt belt (in case of multiple conveyors, snapping of one belt at a time) shall be considered. (iv) Special loads if any f)
Gallery girders and floor shall be designed for the following live loads,inclusive of spillage loads on floors. i) Walkway/Supporting beams for floor - 4.0 KN/m² ii Under the conveyor belt - 0.75 KN/m² iii) Gallery girder, for floor load of - 3.0 KN/m²
g)
Dust load on roof of junction house and conveyor galleries shall be considered as follows: i. For building and structures located at a distance of 300m from the dust producing units - 0.5 KN/m² ii. At a distance of 300 m to 800 m from the dust producing unit - 0.25 KN/m² As per technological requirements, provision of supporting the following, and load arising thereof shall be considered in the design of conveyor gallery. i) Ventilation duct. ii) Electrical cables/cable racks. iii) Fire Fighting equipment. Junction house floors shall be designed for the following loads: i) Live load on floor - 5.0 KN/m² ii) Tension from conveyor belt ii) Load duee to equipment located on floor. iv) Load due to jamming of chutes. v) Erection loads anywhere on the floor.
h)
i)
18.5
j)
Combination of loads The various loads specified shall be combined in accordance with clause 8.0 of IS: 875 (Part-5)-1987 1987 to give the most severe loading condition for design of structures.
k)
Stress enhancements Permissible limits of stress may be increased, wherever permissible, in accordance with IS:800-1984.
Limiting deflection a. b.
The deflection shall be limited in various elements of structures in accordance with clause 3.13 IS: 800-1984. 1984. In addition following limitation in deflection shall be observed in design:
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i) ii) iii)
18.6
Gallery Trusses Top of End portal of gallery truss Traverse deflection of top of Trestle
Span / 400 H / 325 where H =Height of portal above beams H/1000 where H = Height of trestle above foundation
FABRICATION OF STEEL STRUCTURES
18.6.1 Drawings The Contractor shall prepare fabrication drawings, erection drawings, bill of materials, drawing office despatch lists / shipping documents, schedule of bolts and nuts and as built drawings. All drawing work shall be in metric system and all writing work shall be in English. The work shall be carried out as described in General Technical Specifications for structural s works. 18.6.2 Material of Construction 18.6.2.1All steel and other materials used for steelwork and in association with steelwork shall conform to appropriate Indian standards. Only tested materials shall be used unless written authority is obtained for the use of untested materials for certain secondary structural members. Unless otherwise specified in the drawings i. All rolled sections and plates upto 20 mm thk. Shall conform to Grade-E250 Grade & quality A of IS: 2062-2006 2006 and shall generally be of tested quality. ii. Plates above 20 mm thk. and plated structures subjected to dynamic loading shall conform to Grade-E Grade 250 & quality B as per IS: 2062-2006. iii. For High Tensile steel requirements, material conforming to IS: 8500 or SAILSAIL MA (HYA or HYB) shall be used. 18.6.2.2
Steel sheets shall conform to IS: 1079.
18.6.2.3 18.6.2.4
18.6.2.7 18.6.2.8
Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst 240) Corrugated Galvanised Sheets shall conform to IS: 277 with appropriate Zinc coating for the selected thickness of sheet on roof and sides. (1.0mm thk for roof and 0.8mm thk for sides) Aluminium industrial troughed sheets conforming to IS: 1254 shall be used as follows: i) On roof - 0.91mm thick ii) On side walls - 0.71mm thick Translucent sheets shall be fibre glass reinforced polyester sheets of matching profile as per IS: 12866. Colour coated sheets shall be as per appropriate standard. Gutters shall be of copper bearing steel conforming to Grade "A" as per IS:2062.
18.6.2.9
Rails shall conform to IS: 3443.
18.6.2.5 18.6.2.6
18.6.2.10 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for precision and semi precision hexagonal bolts) of property class 6.4unless otherwise specified. Washers shall conform to IS: 6610 Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy
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18.6.2.11 All tapered washer shall be as per IS: 5372 5372 for channels, and IS: 5374 for Joists. Spring washers shall conform to IS: 3063. 18.6.2.12 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts shall conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS: 6623 66 & IS:6649 respectively. IS:814 2004. Electrode to be used 18.6.2.13 Covered electrodes for arc welding shall conform to IS:814–2004. for submerged arc welding shall conform specification IS: 7280-1974. Alternatively Covered electrodes for arc welding shall confirm to AWS Specifications and shall be as follows. - E 6013 for all fillet welds of IS 2062 steel dr E250 , quality A & B - E 7018 for all fillet welds of SAIL-MA SAIL 350 HYA steel - E 7018 for all but welds including site welds irrespective of the quality of steel.Viz. ste IS 2062 gr E250 , quality A , B or SAILMA-350 SAILMA HYA steel. 18.6.2.14 Certified mill test reports of materials used in the work shall be made available for inspection by the Owner / Consultant upon request. 18.6.3 Fabrication 18.6.3.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or their equivalent foreign national standard of the country of origin of supply unless otherwise specified, and in conformity with various clauses of the Technical Specification. herever practicable and wherever perfect matching of parts is required at site, members 18.6.3.2 Wherever shall be shop assembled before despatch to minimise site work. Parts not completely assembled in the shop shall be secured, to the extent possible, to prevent damage during du despatch. 18.6.3.3 ERECTION OF STEEL STRUCTURES 18.6.3.3.1 Scope The scope of work under erection includes in addition to provision of erection and transport equipments, tools and tackles, consumables, materials, labour and supervision, the following: a) Storing and stacking at site of erection of all fabricated structural components/ units/assemblies till the time of erection. b) Transportation of structures at site. c) Receiving at site of structures including site handling /movement, unloading, storing and stacking at site of erection of technological structures such as bunkers and the related structures d) All minor rectification / modification such as :
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e)
f) g) h)
i) j) k) l) m) n) o)
i) Removal of bends, kinks, twists, etc. for parts damaged during transportation and handling; ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of site connections; iii) Reaming for use of next higher size bolt for holes which do not register or which are damaged. iv) Welding of connections in place of bolting bolting for which holes are either not drilled at all or wrongly drilled during fabrication. Other rectification work such as i) Re-fabrication fabrication of parts, damaged beyond repair during transportation and handling or incorrectly fabricated. ii) Fabrication of partss omitted during fabrication by oversight or subsequently found necessary. drilling of holes which do not register and which cannot be reamed iii) Plug-welding and re-drilling for use of next higher size bolt. Fabrication of minor items/missing items or such important important items as directed by the Owner / Consultant. Assembly at site of steel structural components wherever required including temporary supports and staging. Making arrangements for and providing all facilities for conducting ultrasonic X-ray X or gamma ray tests on welds; getting the tests conducted by reputed testing laboratories, making available test films/ graphs,reports and interpretation. Rectifying at site, damaged portions of shop primer by cleaning and touchup paint. Erection of structures including making connections by bolts/high strength friction grip bolts / welding. Alignment of all structures true to line, level plumb and dimensions within specified limits of tolerances as per IS :12843 “Tolerance for Erection of Steel Structures”. Application of second coat of primer paint and two coats of finishing paint at site after erection. Grouting of all column bases after proper alignment of columns and only after obtaining clearance from Owner / Consultant. Conducting preliminary acceptance and final acceptance a tests. Preparation of as built drawings, preparing of sketches/drawings to suit field engineering decisions, availability of material, convenience of fabrication, transportation and erection and changes during fabrication and erection. All such works are subject to approval by the Owner / Consultant.
18.6.4 PAINTING OF BUILDING STEEL STRUCTURES 18.6.4.1All steel structural work shall be painted as follows unless otherwise stated in the drawing / Technical Specification.
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18.6.4.2 Surface preparation The steel surface which is to be painted shall be cleaned of dirt and grease, and the heavier layers of rust shall be removed by chipping prior to actual surface preparation to a specified grade. Following are the type and standards of surface preparation to be followed based on the requirement of a particular painting system or as specified in the design drawings. Manual/Power tool cleaning :: Manual/Power tool cleaning shall be done as per Grade St-2 St or St-3 3 of Swedish Standard Institution Institution SIS 05 5900 or cl.6.2.1.1 & 6.2.1.2 of IS : 1477 - 1987 (Part - 1). Grade St-2 :- Thorough scraping and wire brushing, machine brushing, grinding etc. This grade of preparation shall remove loose mill scale, rust cleaner or with clean compressed air or clean brush. After preparation, the surface should have a faint metallic sheen. The appearance shall correspond to the prints designated St-2. St 2. If no grade of surface preparation is specified, St-2 St grade of preparation as per Swedish Standard shall be followed. 18.6.4.3 Paint System (i) Surface preparation :: St-2 (ii) Primer paint:- Two coats of zinc phosphate in phenolic alkyd medium (35microns/coat). (iii) Finishing paint:- Two coats of synthetic enamel (25 microns/coat) conforming to IS : 2932 - 1974. All paints shall be of approved and shade as per Purchaser / Consultant's requirements. 18.6.4.4 Paint and Painting Manufacture of paints, mixing of paints, etc. shall be generally according to the relevant IS codes of practice. Generally compatibility between primer intermediate and finishing paint shall be certified by the paint manufacturer supplying the paints. Guarantee period shall commerce from the date of completion of finishing coat of paint on entire structures. The guarantee period shall be indicated depending on the type of surface preparation and system of painting. To fulfill this obligations, the Contractor may obtain from the painting manufacturer, guarantee for the performance of paint/painted surfaces. Application of paint shall be by spraying or brushing as per IS : 486-1983 1983 and IS : 487-1985 487 and in uniform layers of 50% overlapping strokes by skilled painters. Painting shall not be done when the temperature is less than 5 degree C or more than 45 degree C and relative humidity is more than 85% 85% unless manufacturer's recommendations permit. Also painting
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shall not be done in foggy weather. During application, paint agitation must be provided where such agitation is recommended by the manufacturer. Painting shall be applied at painting manufacturer's manufacturer's recommended rates. The number of coats shall be such that minimum dry film thickness specified is achieved. The dry film thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring gauges to ensure specified DFT. All structures shall receive one coats of primer paint at shop after fabrication before despatch after surface preparation has been done as per requirements. Unless otherwise specified all structures after erection shall be given one coat of primer and two coats of finishing shing paint of approved colour and quality. The under coat shall have different tint to distinguish the same from the finishing coat. The proposed make, quality and shade of paint shall have the approval of Purchaser / Consultant.
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SECTION 5 1.0
INTRODUCTION This part covers technical requirements which will form an integral part of the Contract. The following provisions shall supplement all the detailed technical requirements brought out in the Technical Specifications and the Technical Data Sheets.
2.0
BRAND NAME Whenever a material or article is specified or described by the name of a particular brand, b manufacturer or vendor, the specific item mentioned shall be understood to be indicative of the function and quality desired, and not restrictive; other manufacturer's products may be considered provided sufficient information is furnished to enable the Employer to determine that the products proposed are equivalent to those named.
3.0
COMPLETENESS OF FACILITIES
3.1
Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant shall shall be engineered and designed in accordance with the specification requirement. All engineering and associated services are required to ensure that a completely engineered plant is provided.
3.2
All equipments furnished by the Contractor shall be complete in every respect, with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or those needed for erection, completion and safe operation & maintenance maintenan of the equipment and for the safety of the operating personnel, as required by applicable codes, though they may not have been specifically detailed in the respective specifications, unless included in the list of exclusions. All similar standard components/ components/ parts of similar standard equipment provided, shall be interchangeable with one another.
4.0
CODES & STANDARDS
4.1
In addition to the codes and standards specifically mentioned in the relevant technical specifications for the equipment / plant / system, system, all equipment parts, systems and works covered under this specification shall comply with all currently applicable statutory regulations and safety codes, including the following: a. Bureau of Indian Standards (BIS) b. Indian electricity act c. Indian electricity city rules d. Indian Explosives Act e. Indian Factories Act and State Factories Act f. Indian Boiler Regulations (IBR) g. Regulations of the Central Pollution Control Board, India h. Regulations of the Ministry of Environment & Forest (MoEF), Government of India
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i. Pollution n Control Regulations of Department of Environment, Government of India j. State Pollution Control Board. k. Rules for Electrical installation by Tariff Advisory Committee (TAC). l. Guideline for wagon tippler – G33 Rev.01 of May 2010. m. Any other statutory codes / standards / regulations, as may be applicable. 4.2
Unless covered otherwise by Indian codes & standards and in case nothing to the contrary is specifically mentioned elsewhere in the specifications, the latest editions (as applicable as on date of bid opening), pening), of the codes and standards given below shall also apply: (a.) Japanese Industrial Standards (JIS) (b.) American National Standards Institute (ANSI) (c.) American Society of Testing and Materials (ASTM) (d.) American Society of Mechanical Engineers (ASME) (e.) American Petroleum Institute (API) (f.) Standards of the Hydraulic Institute, U.S.A. (g.) International Organisation for Standardization (ISO) (h.) Tubular Exchanger Manufacturer's Association (TEMA) (i.) American Welding Society (AWS) (j.) National Electrical Manufacturers Association (NEMA) (k.) National Fire Protection Association (NFPA) (l.) International Electro-Technical Electro Commission (IEC) (m.) Expansion Joint Manufacturers Association (EJMA) (n.) Heat Exchange Institute (HEI)
4.3
In thee event of any conflict between the codes and standards referred to in the above clauses and the requirement of this specification, the requirement of Technical Specification shall govern.
4.4
In case of any change in codes, standards & regulations between between the date of bid opening and the date when vendors proceed with fabrication, the Employer shall have the option to incorporate the changed requirements or to retain the original standard. It shall be the responsibility of the Contractor to bring to the notice notice of the Employer such changes and advise Employer of the resulting effect.
4.5
EQUIPMENT FUNCTIONAL GUARANTEE The functional guarantees of the equipment and the system under the scope of the Contract is given elsewhere in the technical specification. These guarantees shall supplement the general provisions covered under General Conditions of Contract.
4.6
DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS
4.6.1
Design of Facilities All thee design procedures, systems and components proposed shall have already been adequately developed and shall have demonstrated good reliability under similar conditions elsewhere. The Contractor shall be responsible for the selection and design of appropriate appropria
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equipments to provide the best co-ordinated co ordinated performance of the entire system. The basic requirements are detailed out in various clauses of the Technical Specifications. The design of various components, assemblies and subassemblies shall be done so that tha it facilitates easy field assembly and dismantling. All the rotating components shall be so selected that the natural frequency of the complete unit is not critical or close to the operating range of the unit. 4.7
DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED FURNISHED BY CONTRACTOR
4.7.1
Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant and equipment shall be fully integrated, engineered and designed to perform in accordance with the technical specification. All engineering and technical services required ensuring a completely engineered plant shall be provided in respect of mechanical, electrical, control & instrumentation, civil & structural works as per the scope. The Contractor shall shall furnish engineering data/drgs. in accordance with the schedule of information as specified in Technical Specification and data sheet.
4.7.2
The number of copies/prints/CD-ROMs/manuals copies/prints/CD ROMs/manuals to be furnished for various types of documents is given in Section 5.. Distribution schedule shall be informed to successful Contractor.
4.7.3
The documentation that shall be provided by the Contractor is indicated in the various sections of specification. This documentation shall include but not be limited to the following :
4.8
INSTRUCTION MANUALS The Contractor shall submit to the Employer, Instruction Manuals for all the equipments covered under the Contract. The Instruction manuals shall contain full details required for erection, commissioning, operation and maintenance of each equipment. The manual ma shall be specifically compiled for this project. The Instruction Manuals shall comprise of the following.
4.8.1
Erection Manuals The erection manuals shall be submitted prior to the commencement of erection activities of particular equipment/system. equipment/system. The erection manual should contain the following as a minimum. a) Erection strategy. b) Sequence of erection. c) Erection instructions. d) Critical checks and permissible deviation/tolerances. e) List of tool, tackles, heavy equipments like cranes, dozers, etc. f) Bill of Materials g) Procedure for erection. h) General safety procedures to followed during erection/installation.
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i) Procedure for initial checking after erection. j) Procedure for testing and acceptance norms. k) Procedure / Check list for f pre-commissioning activities. l) Procedure / Check list for commissioning of the system. m) Safety precautions to be followed in electrical supply distribution during erection 4.8.2
Operation & Maintenance Manuals i. The operating and maintenance instructions instructions together with drawings (other than shop drawings) of the equipment, as completed, shall be in sufficient detail to enable the Employer to operate, maintain, dismantle, reassemble and adjust all parts of the equipment. They shall give a step by step step procedure for all operations likely to be carried out during the life of the plant / equipment including, operation, maintenance, dismantling and repair including periodical activities wherever required. Each manual shall also include a complete set of drawings of the equipment. ii. If after the commissioning and initial operation of the plant, the manuals require any modification / additions / changes, the same shall be incorporated and the updated final instruction manuals shall be submitted to the Employer Emp for records. iii. A separate section of the manual shall be for each size/ type of equipment and shall contain a detailed description of construction and operation, together with all relevant pamphlets and drawings. iv. The manuals shall include the following: a) List of spare parts along with their drawing and catalogues and procedure for ordering spares. b) Lubrication Schedule including charts showing lubrication checking, testing and replacement procedure to be carried daily, weekly, monthly & at longer intervals to ensure trouble free operation. c) Where applicable, fault location charts shall be included to facilitate finding the cause of mal-operation operation or break down. v. Detailed specifications for all the consumables including lubricant oils, greases, chemicals che etc. system/equipment/assembly/subassembly - wise required for the complete plant. vi. On completion of erection, a complete list of bearings / equipment giving their location, and identification marks etc. shall also be furnished to the Employer indicating lubrication method for each type/category of bearing.
4.8.3
Project Completion Report The Contractor shall submit a Project Completion Report at the time of handing over the plant.
4.8.4
DRAWINGS (a.) All documents submitted by the Contractor for Employer's review shall be in electronic form (soft copies) along with the number of hard copies. The soft copies to be supplied shall be either in CDs, or through direct transfer via E-mail, E mail, etc. depending upon the nature/volume/size of the document. The drawings submitted for approval could be in the Image form.
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(b.) Final copies of the approved drawings shall be submitted in vector form on CDROM along with the requisite number of hard copies. (c.) All documents/text information shall be in latest version of MS Office. (d.) All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail indicating the type, size, arrangement, weight of each component for packing and shipment, the external connection, fixing arrangement arrangeme required, the dimensions required for installation and interconnections with other equipments and materials, clearance and spaces required between various portions of equipment and any other information specifically requested in the drawing schedules. (e.) Each ach drawing submitted by the Contractor (including those of sub-vendors) sub vendors) shall bear a title block at the right hand bottom corner with clear mention of the name of the Employer, the system designation, the specifications title, the specification number, the th name of the Project, drawing number and revisions. If standard catalogue pages are submitted the applicable items shall be indicated therein. All titles, notings, markings and writings on the drawing shall be in English. All the dimensions should be in metric m units. sub vendors) shall bear Employer’s (f.) The drawings submitted by the Contractor (or their sub-vendors) drawing number in addition to contractor’s (their sub-vendor’s) sub vendor’s) own drawing number. Employer’s drawing numbering system shall be made available to the successful succe Contractor so as to enable him to assign Employer’s drawing numbers to the drawings to be submitted by him during the course of execution of the Contract. (g.) The Contractor shall also furnish a “Master Drawing List” which shall be a comprehensive list of all drawings/ documents/ calculations envisaged to be furnished by him during the detailed engineering to the Employer in line with engineering information flow schedule (to be tied up with successful Contractor). Such list should clearly indicate the purpose purpose of submission of these drawings i.e. “FOR APPROVAL” or “FOR INFORMATION ONLY”. (h.) Similarly, all the drawings/ documents submitted by the Contractor during detailed engineering stage shall be stamped “FOR APPROVAL” or “FOR INFORMATION” prior to submission. (i.) The furnishing of detailed engineering data and drawings by the Contractor shall be in accordance with the time schedule for the project. The review of these documents/ data/ drawings by the Employer will cover only general conformance of the data/ drawings/ awings/ documents to the specifications and contract, interfaces with the equipments provided by others and external connections & dimensions which might affect plant layout. The review by the Employer should not be construed to be a thorough review of all dimensions, quantities and details of the equipments, materials, any devices or items indicated or the accuracy of the information submitted. The review and/ or approval by the Employer / Project Manager shall not relieve the Contractor of any of his responsibilities responsibilities and liabilities under this contract. (j.) After the approval of the drawings, further work by the Contractor shall be in strict accordance with these approved drawings and no deviation shall be permitted without the written approval of the Employer. Employe
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(k.) All manufacturing, fabrication and execution of work in connection with the equipment / system, prior to the approval of the drawings, shall be at the Contractor’s risk. The Contractor is expected not to make any changes in the design of the equipment /system, system, once they are approved by the Employer. However, if some changes are necessitated in the design of the equipment/ system at a later date, the Contractor may do so, but such changes shall promptly be brought to the notice of the Employer indicating the reasons for the change and get the revised drawing approved again in strict conformance to the provisions of the Technical Specification. (l.) Drawings shall include all installations and detailed piping and wiring drawings. (m.) Assessing & anticipating the requirement requirement and supply of all piping and equipment shall be done by the contractor well in advance so as not to hinder the progress of piping & equipment erection, subsequent system charging and its effective draining & venting arrangement as per site suitability. suita (n.) Any software used by the contractor shall be given to the project manager and concerned engineer of employer. The contractor shall make the engineer of the employer aware of the programme. Any computer aided programme shall be approved subject to giving entire detail to the project manager. (o.) Drawings must be checked by the Contractor in terms of its completeness, data adequacy and relevance with respect to Engineering schedule prior to submission to the Employer. In case drawings are found to be submitted submitted without proper endorsement for checking by the Contractor, the same shall not be reviewed and returned to the Contractor for re-submission. submission. The contractor shall make a visit to site to see the existing facilities and understand the layout completely completely and collect all necessary data / drawings at site which are needed as an input to the engineering. The contractor shall do the complete engineering including interfacing and integration of all his equipment, systems & facilities within his scope of work as well as interface engineering & integration of systems, facilities, equipment & works under Employer’s scope and submit all necessary drawings/ documents for the same. (p.) All drawings shall be reviewed and approved by Engineering coordinator, including the following drawings / data which require specific approval. 1. Data sheets for various equipments / systems. 2. Field testing procedures for various equipment and piping system. 3. Pre commissioning / commissioning procedures including flushing, Chemical cleaning, g, steam blowing and hydro test etc. (Wherever applicable) O&M manual shall also be reviewed and approved by Employer. The content of O&M manual shall be as specified elsewhere in the specification. 4. Guarantee test procedures. 5. Any other drawings that may be required by the Engineer from time to time.) 6. Data furnished in the bid shall be binding on the contractor even if superior to the technical specification requirement and any revision shall be done with the owner/RITES /RITES’s agreement.
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(q.) The Contractor shall submit adequate prints of drawing / data / document for Employer’s review and approval. The Employer shall review the drawings and return one (1) copy to the Contractor authorizing either to proceed with manufacture or fabrication, or marked to show changes changes desired. When changes are required, drawings shall be re-submitted submitted promptly, with revisions clearly marked, for final review. Any delays arising out of the failure of the Contractor to submit/rectify and resubmit in time shall not be accepted as a reason for delay in the contract schedule (r.) Upon review of each drawing, depending on the correctness and completeness of the drawing, the same will be categorised and approval accorded in one of the following categories : • CATEGORY I Approved • CATEGORY II Approved subject to incorporation of comments/ modification as noted. Resubmit revised drawing incorporating the Comments • CATEGORY III Not approved. Resubmit revised drawings for approval after incorporating comments/modification as noted. • CATEGORY IV For information informat and records. (s.) Vendor shall resubmit the drawings approved under Category II and III within three (3) weeks of receipt of comments on the drawings, incorporating all comments. Every revision of the drawing shall bear a revision index wherein such revisions revisio shall be highlighted in the form of description or marked up in the drawing identifying the same with relevant revision Number enclosed in a triangle (eg. 1, 2, 3 etc). • In case Vendor does not agree with any specific comment, he shall furnish the explanation for the same to owner / consultant for consideration. In all such cases vendor shall necessarily enclose explanations along with the revised drawing (taking care of balance comments) to avoid any delay and/or duplication in review work. •
It is responsibility of the Vendor to get all the drawings approved in the Category I & IV (as the case may be) and complete engineering activities within the agreed schedule. Any delay arising out of submission and modification of drawings shall not alter the contract ontract completion schedule. Vendor shall not make any changes in the portions of the drawing other than those commented upon. If changes are required to be made in the portions already approved, the vendor shall resubmit the drawing identifying the changes change for owner/RITES’s ’s review and approval.
(t.) If Vendor fails to resubmit the drawings as per the schedule, construction work at site will not be held up and work will be carried out on the basis of comments furnished on previous issues of the drawing. These comments comments will be taken care by the contractor while submitting the revised drawing. (u.) All engineering data submitted by the Contractor after final process including review and approval by the Project Manager/ Employer shall form part of the contract documentss and the entire works covered under these specification shall be performed in strict conformity with technical specifications unless otherwise expressly requested by the Project Manager in writing.
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(v.) After final acceptance of individual equipment / system by by the Employer, the Contractor will update all original drawings and documents for the equipment / system to “as built” conditions. 4.8.5
ENGINEERING INFORMATION SUBMISSION SCHEDULE Prior to the award of Contract, a Detailed Engineering Information Submission Submi Schedule shall be tied up with the Employer. For this, the Contractor shall furnish a detailed list of engineering information along with the proposed submission schedule. This list would be a comprehensive one including all engineering data / drawings drawings / information for all bought out items and manufactured items. The information shall be categorised into the following parts. Information that shall be submitted for the approval of the Employer before proceeding further, and Information that would be submitted for Employer’s information only. The Engineering Information Schedule shall be updated month wise. The schedule should allow adequate time for proper review and incorporation of changes/ modifications, if any, to meet the contract without affecting affecting the equipment delivery schedule and overall project schedule. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performancee and progress.
4.9
ENGINEERING COORDINATION PROCEDURE
4.9.1
Identification of Principal Engineering Coordinators The following principal coordinators will be identified by respective organisations at time of award of contract RITES’ COORDINATORS RITES- Engineering Coordinators Name : Designation : Address : a) Postal : b) Telegraphic : TELEX : FAX : TELEPHONE : EMPLOYER’S COORDINATORS NALCO- Engineering Coordinators (NALCO EC) Name : Designation : Address : a) Postal : b) Telegraphic : TELEX :
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FAX : TELEPHONE : ORDINATOR (NALCO SC) NALCO- SITE CO-ORDINATOR Name : Designation : Address : a) Postal : b) Telegraphic : TELEX : FAX : TELEPHONE :
4.9.2
VENDOR ENGINEERING CO-ORDINATOR CO (VENDOR EC) Name : Designation : Address : a) Postal : b) Telegraphic : TELEX : FAX : TELEPHONE : All engineering correspondence shall be in the name of above coordinators on behalf of the respective organisations.
4.9.3 Vendors Drawings (a) The contractor shall furnish, discuss and finalise with the Employer, the engineering information ion flow schedule at the time of award of the contract. The dates for submission of drawings as finalised in the above engineering schedule, shall be strictly adhered to. This is essential for the timely completion of the project. (b) A detailed drive list shall shall be furnished along with the tender. Further drive list shall be submitted to the RITES’s Engineering coordinator within 60 days from the date of award of the contract. s (c) In any case, in order to achieve the project completion dates, the contractor must strictly comply with engineering schedules. (d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be submitted by the contractor to the Engineer within two (2) weeks of the approval. (e) Copies of all approved drgs. (in cat. I & IV) shall be submitted incorporating all site modifications, if any, during construction, erection, commission stages and performance and guarantee testing (till its continuous operation) as ‘As Built Drgs’. (f) The contractor shall use a single transmittal for drgs. Submission. This shall include transmittal numbers and date, number of copies being sent, names of the agencies to whom are all the copies being sent drg. numbers and titles, remarks or special notes if any etc. (g) All manufacturing and fabrication work in connection with the equipments prior to the approval of the drg. shall be at contractors risks. (h) Approval of contractor’s drgs. or work
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by the Engineer shall not relieve the contractor of any of his responsibilities or liabilities under the contract. 4.9.4
Erection Drawings (a) Contractor shall furnish erection drawings for the guidance of his/ RITES’s site staff at least 4 weeks before scheduled commencement of erection or the first shipment, whicheverr is earlier. These shall generally comprise of fabrication/assembly drawings, various component/part details drawings, assembly, clearance, data requirements etc. The drawings shall contain details of components/ equipment with identification numbers, match ch marks, bills of materials, assembly procedures etc. (b) For all major equipment apart from above details, assembly sequence and instructions with check lists shall be furnished in the form of erection manuals CLAUSE NO.
4.9.5
ENGINEERING PROGRESS AND EXCEPTION REPORT R A report giving the status of each engineering information including the list of drawings/engineering information which remains unapproved for more than one (1) weeks after the date of first submission Drawings which were not submitted as per agreed schedule.
4.9.6
TECHNICAL CO-ORDINATION ORDINATION MEETING (a) The Contractor shall be called upon to organise and attend monthly Design/ Technical Co-ordination ordination Meetings (TCMs) with the owner/owner’s representatives and other Contractors of the Employer during the period of contract. The Contractor shall attend such meetings at his own cost as and when required and fully co-operate co with such persons and agencies involved during the discussions. (b) The Contractor should note that Time is the essence of the contract. In order to expedite the early completion of engineering activities, the Contractor shall submit all drawings as per the agreed Engineering Information Submission Schedule. The drawings submitted by the Contractor will be reviewed by the Employer as far as practicable practica within three (3) weeks from the date of receipt of the drawing .The comments of the Employer shall then be discussed across the table during the above Technical Co-ordination Co ordination Meeting (s) wherein best efforts shall be made by both sides to ensure the approval approval of the drawing. (c) The Contractor shall ensure availability of the concerned experts / consultants/ personnel who are empowered to take necessary decisions during these meetings. (d) Should any drawing remain unapproved for more than one (1)) weeks after it’s first submission, this shall be brought out in the monthly Engineering Progress and Exception Report with reasons thereof. (e) Any delays arising out of failure by the Contractor to incorporate Employer’s comments and resubmit the same during the TCM shall shall be considered as a default and in no case shall entitle the Contractor to alter the Contract completion date.
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4.9.7 DESIGN IMPROVEMENTS The Employer/RITES or the Contractor may propose changes in the specification of the equipment or quality thereof and if the parties agree upon any such changes the specification shall be modified accordingly. If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any changingg the price and/or schedule of completion before the Contractor proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. 4.9.8
EQUIPMENT BASES A cast iron or welded steel base plate shall be provided for all rotating equipment which is to be installed on a concrete base, unless otherwise specifically agreed to by the Employer. Each base plate which support the unit and its drive assembly, shall be be of a neat design with pads for anchoring the units.
4.9.9
PROTECTIVE GUARDS Suitable guards shall be provided for protection of personnel on all exposed rotating and/or moving machine parts. All such guards shall be designed for easy installation and removal for maintenance purpose.
4.9.10 LUBRICANTS, SERVO FLUIDS AND CHEMICALS (a) The Contractor’s scope includes all the first fill of consumables such as oils, lubricants including grease, servo fluids, gases and essential chemicals etc. Consumption of all these thes consumables during the initial operation and final filling after the initial operation shall also be included in the scope of the Contractor. (b) The variety of lubricants shall be kept to a minimum possible. Detailed specifications for the lubricating oil, grease, gases, servo fluids, control fluids, chemicals etc. required for the complete plant covered herein shall be furnished. On completion of erection, a complete list of bearings/ equipment giving their location and identification marks shall be furnished furnis to the Employer along with lubrication requirements. 4.9.11 Lubrication Equipment shall be lubricated by systems designed for continuous operation. Lubricant level indicators shall be furnished and marked to indicate proper levels under both standstill standsti and operating conditions. 4.9.12 Material of Construction All materials used for the construction of the equipment shall be new and shall be in accordance with the requirements of this specification. Materials utilised for various components shall be those which have established themselves for use in such applications. 4.9.13 RATING PLATES, NAME PLATES & LABELS Technical Specifications: Sec-5,General Techn chnical Requirements
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Each main and auxiliary item of plant including instruments shall have permanently attached to it in a conspicuous position, a rating plate of o non-corrosive corrosive material upon which shall be engraved manufacturer’s name, equipment, type or serial number together with details of the ratings, service conditions under which the item of plant in question has been designed to operate. Each item of plantt shall be provided with nameplate or label designating the service of the particular equipment. Such nameplates or labels shall be of white non hygroscopic material with engraved black lettering or alternately, in the case of indoor circuit breakers, starters, starters, etc. of transparent plastic material with suitably coloured lettering engraved on the back. The name plates shall be suitably fixed on both front and rear sides. Items of plant such as valves, which are subject to handling, shall be provided with an engraved chromium plated nameplate or label with engraving filled with enamel.. All segregated phases of conductors or bus ducts, indoor or outdoor, shall be provided with coloured phase plates to clearly identify the phase of the system 4.9.14 TOOLS AND TACKLES The Contractor shall supply with the equipment one complete set of all special tools and tackles and other instruments required for the erection, assembly, disassembly disassembly and proper maintenance of the plant and equipment and systems (including software). These special tools will also include special material handling equipment, jigs and fixtures for maintenance and calibration / readjustment, checking and measurement measurement aids etc. A list of such tools and tackles shall be submitted by the Contractor alongwith the offer. The price of each tool / tackle shall be deemed to have been included in the total bid price. These tools and tackles shall be separately packed and sent sent to site. The Contractor shall also ensure that these tools and tackles are not used by him during erection, commissioning and initial operation. For this period the Contractor should bring his own tools and tackles. All the tools and tackles shall be off reputed make acceptable to the Employer. 4.9.15 Welding If the manufacturer has special requirements relating to the welding procedures for welds at the terminals of the equipments to be per formed by others the requirements shall be submitted to the Employer in advance of commencement of erection work. 4.9.16 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES All equipment/ services are to be painted by the Contractor in accordance with Employer’s standard colour coding scheme, which will be furnished to the Contractor during detailed engineering stage. 4.10
PROTECTION AND PRESERVATIVE SHOP COATING
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4.10.1 PROTECTION All coated surfaces shall be protected against abrasion, impact, discoloration and any other damages. All exposed threaded portions shall be suitably protected with either metallic or a nonmetallic protection device. All ends of all valves and pipings and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage. The parts which are likely to get rusted, due to exposure to weather, should also be properly treated and protected in a suitable manner. All primers/paints/coatings shall take into account the hot humid, corrosive & alkaline, subsoil or over ground environment as the case may be. 4.10.2 Preservative Shop Coating All exposed metallic surfaces subject to corrosion shall be protected by shop application of suitable coatings. All surfaces which will not be easily accessible after the shop assembly, shall be treated beforehand and protected for for the life of the equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and other coatings and prepared in the shop. The surfaces that are to be finish-painted finish painted after installation or require corrosion protection until installation, shall be shop painted with atleast two coats of primer. Transformers and other electrical equipments if included shall be shop finished with one or more coats of primer and two coats of high grade resistance enamel. The finished colors shall be as per manufacturer’s ufacturer’s standards, to be selected and specified by the Employer at a later date. Shop primer for all steel surfaces which will be exposed to operating temperature below 95 degrees Celsius shall be selected by the Contractor after obtaining specific approval ap of the Employer regarding the quality of primer proposed to be applied. Special high temperature primer shall be used on surfaces exposed to temperature higher than 95 degrees Celsius and such primer shall also be subject to the approval of the Employer. Empl All other steel surfaces which are not to be painted shall be coated with suitable rust preventive compound subject to the approval of the Employer. All piping shall be cleaned after shop assembly. Painting for Civil structures shall be done as per relevant part of technical specification 4.11
QUALITY ASSURANCE PROGRAMME The Contractor shall adopt suitable quality assurance programme to ensure that the equipment and services under the scope of contract contract whether manufactured or performed within the Contractor’s works or at his sub-contractor’s sub contractor’s premises or at the Employer’s site or at any other place of work are in accordance with the specifications. Such programmes shall be outlined by the Contractor Contractor and shall be finally accepted by the Employer/authorised representative after discussions before the award of the contract. The QA programme shall be generally in line with IS/ISOIS/ISO 9001.A quality assurance programme of the contractor shall generally coverr the following:
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(a) His organisation structure for the management and implementation of the proposed quality assurance programme (b) Quality System Manual (c) Design Control System (d) Documentation and Data Control System (e) Qualification data for Contractor’s key personnel. (f) The procedure for purchase of materials, parts, components and selection of subsub contractor’s services including vendor analysis, source inspection, incoming raw-material raw inspection, verification of materials purchased etc. (g) System for shop manufacturing manufacturing and site erection controls including process, fabrication and assembly. conforming items and system for corrective actions and resolution of (h) Control of non-conforming deviations. (i) Inspection and test procedure both for manufacture and field activities. (j) Control of calibration and testing of measuring testing equipment. (k) System for Quality Audits. (l) System for identification and appraisal of inspection status. (m) System for authorising release of manufactured product to the Employer. (n) System for handling, storage and delivery. (o) System for maintenance of records, and (p) Quality plans for manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component. 4.12
GENERAL REQUIREMENTS - QUALITY ASSURANCE
4.12.1 All materials, components and equipment covered under this specification shall be procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. Programme. An indicative programme of inspection/tests to be carried out by the contractor for some of the major items is given in the respective technical specification. This is, however, not intended to form a comprehensive programme as it is the contractor’s responsibility to draw up and implement such programme duly approved by the Employer. The detailed Quality Plans for manufacturing and field activities shall be drawn up by the Contractor and will be submitted to Employer for approval. Schedule of finalisation ation of such quality plans will be finalised before award. Monthly progress reports on MQP/FQP submission/approval shall be furnished on enclosed format No. QS-01-QAI-P-02/F1. e various 4.12.2 Manufacturing Quality Plan will detail out for all the components and equipment, tests/inspection, to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Contractor’s/ Sub-contractor’s/ sub-supplier's supplier's Quality Control Organisation, Organisation, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. The Quality Plan shall be submitted on electronic media e.g. floppy or E-mail E in addition to hard copy, for review and approval. After approval the same shall be submitted in compiled form on CD--ROM. Technical Specifications: Sec-5,General Techn chnical Requirements
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4.12.3 Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc. tc. to be followed by the Contractor’s "Site Quality Control Organisation", during various stages of site activities starting from receipt of materials/equipment at site. 4.12.4 The Contractor shall also furnish copies of the reference documents/plant standards/acceptance ndards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans. These Quality Plans and reference documents/standards etc. will be subject to Employer’s approval without which manufacturer shall not proceed. proce These approved documents shall form a part of the contract. In these approved Quality Plans, Employer shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in presence of the Employer’s Project Manager or his authorised representative and beyond which the work will not proceed without consent of Employer in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Employer along with technical justification justification for approval and dispositioning. 4.12.5 No material shall be despatched from the manufacturer’s works before the same is accepted, subsequent to predespatch final inspection including verification of records of all previous tests/inspections by Employer’s Employer’s Project Manager/Authorised representative and duly authorised for despatch by issuance of Material Despatch Clearance Certificate (MDCC). 4.12.6 All material used for equipment manufacture including casting and forging etc. shall be of tested quality lity as per relevant codes/standards. Details of results of the tests conducted to determine the mechanical properties; chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature emperature chart. Tests shall be carried out as per applicable material standards and/or agreed details. 4.12.7 The contractor shall submit to the Employer Field Welding Schedule for field welding activities in the enclosed format No.: QS-01-QAI-P-02/F3. QS The field welding schedule shall be submitted to the Employer along with all supporting documents, like welding procedures, heat treatment procedures, NDT procedures etc. at least ninety days before schedule start of erection work at site. 4.12.8 All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section IX/BS-4870 IX/BS 4870 or other International equivalent standard acceptable to the Employer. All welding/brazing procedures shall be submitted submitte to the Employer or its authorized representative for approval prior to carrying out the welding/brazing. 4.12.9 All brazers, welders and welding operators employed on any part of the contract either in Contractor’s/sub-contractor’s contractor’s works or at site or elsewhere elsewhere shall be qualified as per ASME Section-IX or BS-4871 4871 or other equivalent International Standards acceptable to the Employer.
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4.12.10 Welding procedure qualification & Welder qualification test results shall be furnished to the Employer for approval. al. However, where required by the Employer, tests shall be conducted in presence of Employer/authorised representative. 4.12.11 Unless otherwise proven and specifically agreed with the Employer, welding of dissimilar materials and high alloy materials shall sh be carried out at shop only. 4.12.12No welding shall be carried out on cast iron components for repair. 4.12.13 All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes. tive examination shall be performed in accordance with written procedures 4.12.14 All non-destructive as per International Standards, The NDT operator shall be qualified as per SNT-TC-IA SNT (of the American Society of non-destructive non destructive examination). NDT shall be recorded in a report, which whic includes details of methods and equipment used, result/evaluation, job data and identification of personnel employed and details of correlation of the test report with the job. All Bar stock / forgings of diameter equal to or greater than 50mm shall be ultrasonically u tested. In general all plates of thickness equal to or greater than 40mm and for pressure parts, pates of thickness equal to or greater than 25mm shall be ultrasonically tested unless as specified otherwise in respective equipment specification. specificati 4.12.15The Contractor shall list out all major items/ equipment/ components to be manufactured in house as well as procured from sub-contractors. sub All the subcontractor proposed by the Contractor for procurement of major bought out items including castings, forging, semisemi finished and finished components/equipment etc., list of which shall be drawn up by the Contractor and finalised with the Employer, shall be subject to Employer's approval. The contractor’s proposal shall include vendor’s facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. along with his own technical evaluation ation for identified sub-contractors sub contractors enclosed and shall be submitted to the Employer for approval within the period agreed at the time of pre-awards pre discussion and identified in "DR" category prior to any procurement. Monthly progress reports on subsub contractor ctor detail submission / approval shall be furnished. Such vendor approval shall not relieve the contractor from any obligation, duty or responsibility under the contract. 4.12.16For components/equipment procured by the contractors for the purpose of the contract, after obtaining the written approval of the Employer, the contractor’s purchase specifications and inquiries shall call for quality plans to be submitted by the suppliers. The quality plans called for from the sub-contractor sub shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the vendor’s quality control organisation, the relevant reference documents/standards used, acceptance level, inspection of documentation raised, etc. Such Such quality plans of the successful vendors shall be finalised with the Employer and such approved Quality Plans shall form a part of the purchase order/contract between the Contractor and sub-contractor. sub contractor. Within three weeks of the release of the purchase orders orders /contracts for such bought out items /components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the Employer on
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the monthly basis by the Contractor Contractor along with a report of the Purchase Order placed so far for the contract. ** 4.12.17Employer reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractor’s or their sub-contractor’s sub contractor’s quality management and control activities. The contractor shall provide all necessary assistance to enable the Employer carry out such audit and surveillance. 4.12.18The contractor shall carry out an inspection and testing programme during manufacture in his work and that of his sub-contractor’s sub contractor’s and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. Contractor shallll carry out all tests/inspection required to establish that the items/equipment conform to requirements of the specification and the relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved quality plan. pla 4.12.19Quality audit/surveillance/approval of the results of the tests and inspection will not, however, prejudice the right of the Employer to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc. or all spares and replacement items, the quality requirements as agreed for the main 4.12.20 For equipment supply shall be applicable. 4.12.21 Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Employer/ authorised representative. 4.13
QA DOCUMENTATION PACKAGE The Contractor shall be required to submit the QA Documentation in two hard copies and two CD ROMs.
4.13.1 Each QA Documentation shall have a project specific Cover Sheet bearing name & identification ation number of equipment and including an index of its contents with page control on each document. The QA Documentation file shall be progressively completed by the Supplier’s sub-supplier supplier to allow regular reviews by all parties during the manufacturing. The final quality document will be compiled and issued at the final assembly place of equipment before despatch. However CD-Rom CD Rom may be issued not later than three weeks. below: 4.13.2 Typical contents of QA Documentation is as below:(a) Quality Plan (b) Material mill test reports on components as specified by the specification and approved Quality Plans.
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(c) Manufacturer / works test reports/results for testing required as per applicable codes and standard referred in the specification and approved Quality Plans. (d) Non-destructive ructive examination results /reports including radiography interpretation reports. Sketches/drawings used for indicating the method of traceability of the radiographs to the location on the equipment. (e) Heat Treatment Certificate/Record (Time(Time temperature Chart) (f) All the accepted Non-conformance Non conformance Reports (Major/Minor) / deviation, including complete technical details / repair procedure). (g) Inspection reports duly signed by the Inspector of the Employer and Contractor for the agreed Customer Hold Points. (h) Certificate te of Conformance (COC) wherever applicable. (i) MDCC 4.13.3 Similarly, the contractor shall be required to submit two sets (two hard copies and two CD ROMs), containing QA Documentation pertaining to field activities as per Approved Field Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual system. 4.13.4 Before despatch / commissioning of any equipment, the Supplier shall make sure that the corresponding quality document or in the case of protracted phased deliveries, the t applicable section of the quality document file is completed. The supplier will then notify the Inspector regarding the readiness of the quality document (or applicable section) for review. If the result of the review carried out by the Inspector is satisfactory, satisfactory, the Inspector shall stamp the quality document (or applicable section) for release. If the quality document is unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to finalize the quality document (or applicable applicable section) by time compatible with the requirements as per contract documents. When it is done, the quality document (or applicable section) is stamped by the Inspector. If a decision is made despatch, whereas all outstanding actions cannot be readily cleared cleared for the release of the quality document by that time. The supplier shall immediately, upon shipment of the equipment, send a copy of the quality document Review Status signed by the Supplier Representative to the Inspector and notify of the committed date for the completion of all outstanding actions & submission. The Inspector shall stamp the quality document for applicable section when it is effectively completed. The submission of QA documentation package shall not be later than 3 weeks after the despatch spatch of equipment. 4.13.5 TRANSMISSION OF QA DOCUMENTATION On release of QA Documentation by Inspector, one set of quality document shall be forwarded to Corporate Quality Assurance Department and other set to respective Project Site of Employer. For the the particular case of phased deliveries, the complete quality document to the Employer shall be issued not later than 3 weeks after the date of the last delivery of equipment. 4.14
Project Manager’s Supervision
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4.14.1 To eliminate delays and avoid disputes disputes and litigation, it is agreed between the parties to the Contract that all matters and questions shall be referred to the Project Manager and without prejudice to the provisions of ‘Arbitration’ clause in GCC, the Contractor shall proceed to comply with the Project Manager's decision. 4.14.2 The work shall be performed under the supervision of the Project Manager. The scope of the duties of the Project Manager pursuant to the Contract, will include but not be limited to the following: (a) Interpretation of all the terms and conditions of these documents and specifications: (b) Review and interpretation of all the Contractor’s drawing, engineering data, etc: (c) Witness or his authorised representative to witness tests and trials either at the manufacturer’s works or at site, or at any place where work is performed under the contract : (d) Inspect, accept or reject any equipment, material and work under the contract: (e) Issue certificate of acceptance and/or progressive payment and final payment certificates (f) Review and suggest modifications and improvement in completion schedules from time to time, and (g) Supervise Quality Assurance Programme implementation at all stages of the works. 4.15
INSPECTION, TESTING AND INSPECTION CERTIFICATES
Project Manager and/or his authorized representative (a) The word ‘Inspector’ shall mean the Project and/or an outside inspection agency acting on behalf of the Employer to inspect and examine the materials and workmanship of the works during its manufacture or erection. authorised representative and/or an outside inspection (b) The Project Manager or his duly authorised agency acting on behalf of the Employer shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works works is being manufactured or assembled on other premises or works, the Contractor shall obtain for the Project Manager and for his duly authorised representative permission to inspect as if the works were manufactured or assembled on the Contractor’s own premises remises or works. (c) The Contractor shall give the Project Manager/Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractor’s account except for the expenses of the Inspector’s. The Project Manager/Inspector, Manager/Inspector, unless the witnessing of the tests is virtually waived and confirmed in writing, will attend such tests within fifteen (15) days of the date on which the equipment is noticed as being ready for test/inspection failing which the contractor may may proceed with test which shall be deemed to have been made in the inspector’s presence and he shall forthwith forward to the inspector duly certified copies of test reports in two (2) copies. (d) The Project Manager or Inspector shall within fifteen (15) days days from the date of inspection as defined herein give notice in writing to the Contractor, or any objection to any drawings and all or any equipment and workmanship which is in his opinion not in accordance with the contract. The Contractor shall give due consideration to such objections and shall either Technical Specifications: Sec-5,General Techn chnical Requirements
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make modifications that may be necessary to meet the said objections or shall inform in writing to the Project Manager/Inspector giving reasons therein, that no modifications are necessary to comply with the th contract. (e) When the factory tests have been completed at the Contractor’s or sub-contractor’s sub works, the Project Manager /Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Project Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Contractor’s test certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a certificate shall not prevent the Contractor Contractor from proceeding with the works. The completion of these tests or the issue of the certificates shall not bind the Employer to accept the equipment should it, on further tests after erection be found not to comply with the contract. here the contract provides for tests whether at the premises or works of the (f) In all cases where Contractor or any sub-contractor, contractor, the Contractor, except where otherwise specified shall provide free of charge such items as labour, material, electricity, fuel, water, stores, apparatus pparatus and instruments as may be reasonably demanded by the Project Manager /Inspector or his authorised representatives to carry out effectively such tests on the equipment in accordance with the Contractor and shall give facilities to the Project Manager/Inspector er/Inspector or to his authorised representative to accomplish testing. (g) The inspection by Project Manager / Inspector and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the th agreed Quality Assurance Programme forming a part of the contract. (h) To facilitate advance planning of inspection, the Contractor shall furnish quarterly inspection programme indicating schedule dates of inspection at Customer Hold Point and final inspection ion stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month. (i) All inspection, measuring and test equipment used by contractor shall be calibrated periodically depending on its use and criticality of the test/measurement to be done. The Contractor shall maintain all the relevant records of periodic calibration and instrument identification, and shall produce the same for inspection by NALCO. Wherever asked specifically, ically, the contractor shall re-calibrate re calibrate the measuring/test equipment in the presence of Project Manager / Inspector. 4.16
COMMISSIONING AND COMMISSIONING FACILITIES PRE-COMMISSIONING (a) As soon as the facilities or part thereof has been completed operationally and structurally cturally and before start-up, start up, each item of the equipment and systems forming part of facilities shall be thoroughly cleaned and then inspected jointly by the Employer and the Contractor for correctness of and completeness of facility or part thereof and acceptability ceptability for initial pre-commissioning pre commissioning tests, commissioning and start-up start at Site. The list of pre-commissioning commissioning tests to be performed shall be as mutually agreed and
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included in the Contractor’s quality assurance programme as well as those included elsewhere where in the Technical Specifications. pre commissioning/start-up up engineers, specially (b) The Contractor’s pre-commissioning/ identified as far as possible, shall be responsible for carrying out all the prepre commissioning tests at Site. On completion of inspection, inspection, checking and after the prepre commissioning tests are satisfactorily over, the commissioning of the complete facilities shall be commenced during which period the complete facilities, equipments shall be operated integral with sub-systems sub and supporting equipment uipment as a complete plant. (c) The time consumed in the inspection and checking of the units shall be considered as a part of the erection and installation period. (d) The check outs during the pre - commissioning period should be programmed to follow the construction truction completion schedule. Each equipment/system, as it is completed in construction and turned over to RITES/Employer's Employer's commissioning (startup) Engineer(s), should be checked out and cleaned. The checking and inspection of individual systems should then follow a prescribed commissioning documentation [SLs (Standard Check List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by the Employer/RITES. (e) On completion of all pre-commissioning pre commissioning activities / tests and as a part of commissioning the complete facilities shall be put on 'Trial Operation' during which period all necessary adjustments shall be made while operating over the full load range enabling the facilities to be made ready for the Guarantee Tests (f)
The duration of 'Trial Operation' Operation' of the complete facility as an integral unit shall be 30 continuous days with available wagon loads or as to be mutually agreed. agreed The Trial Operation shall be considered successful, provided that each item/part of the facility can operate continuously at the specified operating characteristics, for the period of Trial Operation with all operating parameters within the specified limits and at or near the predicted performance of facility/equipment.
operation with any load shall be counted. (g) For the period of 'Trial Operation', the time of operation (h) A Trial Operation report comprising of observations and recordings of various parameters to be measured in respect of the above Trial Operation shall be prepared by the Contractor. This report, besides recording the details details of the various observations during trial operation shall also include the dates of start and finish of the Trial Operation and shall be signed by the representatives of both the parties. The report shall have sheets, recording all the details of interruptions interruptions occurred, adjustments made and any minor repairs done during the Trial Operation. Based on the observations, necessary modifications/repairs to the plant shall be carried out by the Contractor to the full satisfaction of the Project Manager to enable enable the latter to accord permission to carry out the Guarantee tests on the facilities. However, minor defects which do not
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endanger the safe operation of the equipment, shall not be considered as reasons for with- holding the aforesaid permission ctor shall furnish the commissioning organization chart for review & acceptance Contractor of employer at least eighteen months prior to the schedule date of synchronization of 1st unit. The chart should contain: a) Experience of the Commissioning Engineers. b) Role and responsibilities sponsibilities of the Commissioning Organisation members. c) Expected duration of posting of the above Commissioning Engineers at site. GUARANTEE TESTS
(i)
4.17
(a) The final tests as to the guarantees shall be conducted at Site, by the Contractor. The Contractor's Commissioning and start-up start up Engineers shall make the unit ready for such tests. Such test will be commenced, within a period of three (3) months after the successful completion of Trial Operation. Any extension of time beyond the above three months shall be subject to Employer's approval. (b) These tests shall be binding on both the parties of the Contract to determine compliance of the equipment with the performance guarantee. (c) Any special equipment, tools and tackles required for the successful completion of the Guarantee Tests shall be provided by the Contractor, free of cost. cost The bidder should particularly note that suitable and necessary method and arrangement for the PG test for 1200TPH of the new conveyor integrating into 800 TPH of existing conveyor system has to be made by him/them acceptable to owner/RITES at no extra cost. (d) The guarantee figures and design/performance parameters of the equipment shall be proved by the Contractor during these Guarantee Tests/ and or during the 'Trial operation' as detailed detailed out elsewhere. Should the results of these tests show any deterioration from the guaranteed values, the Contractor shall modify the equipment as required to enable it to meet the guarantees. In such case, the Guarantee Tests shall be repeated and all cost cost for modifications including labour, materials and the cost of additional testing to prove that the equipment meets the guarantees, shall be borne by the Contractor. (e) The specific tests to be conducted on equipment have been brought out in the technical specification. 4.18
Test Codes The provisions outlined in the ASME Performance Test Codes shall be used as a guide for all the above test procedures unless otherwise specified in the technical specifications.
4.19
TAKING OVER Upon successful completion completion of Initial Operations and all the tests conducted to the Employer's satisfaction, the Employer shall issue to the Contractor a Taking over Certificate
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as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably be with held ld nor will the Employer delay the issuance thereof, on account of minor omissions or defects which do not affect the commercial operation and/or cause any serious risk to the equipment. Such certificate shall not relieve the Contractor of any of his obligations ations which otherwise survive, by the terms and conditions of the Contract after issuance of such certificate. 4.20
TRAINING OF EMPLOYER'S PERSONNEL The scope of service under training of Employer’s engineers (min. 3 nos.) shall include a training module in the areas of Operation & Maintenance. Such training should cover the following areas as a minimum in order to enable these personnel to individually take the responsibility of operating and maintaining the wagon tippler system in a manner acceptable accepta to the Employer: The scope of services under training shall also necessarily include training of Employer's personnel. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & operation etc. and shall include all the related areas like Design Design familiarization, training on product design features and product design softwares of major equipment and systems, engineering, manufacturing, erection, commissioning, training on operating features of equipment, quality assurance and testing, plant visits visits and visits to manufacturer's works, exposure to various kinds of problems which may be encountered in fabrication, manufacturing, erection, welding etc. The training module prepared by the contractor, shall be submitted for the Employer’s approval, prior pri to imparting training. Contractor shall furnish in his offer, details of training module(s) covering above requirements which shall be subject to Employer's approval. Consolidated training period included above (for O&M and Engineering) is indicative only. Employer reserves the right to reappropriate the training period between O&M and engineering depending upon the details of training module proposed by the Contractor. Training schedule shall be finalised based on the Contractor's proposal within two (2) months prior to commissioning. In all the above cases, wherever the training of Employer's personnel is arranged at the works of the manufacturer's it shall be noted that the lodging and boarding of the Employer's personnel shall be at the cost of Contractor. Co
4.21 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION In addition to the requirements given in Erection Conditions of Contract (ECC) the following shall also cover: 1. Working platforms should be fenced and shall have means of access. 2. Ladders in accordance ccordance with Employer’s safety rules for construction and erection shall be used. Rungs shall not be welded on columns. All the stairs shall be provided with handrails immediately after its erection. 4.22
NOISE LEVEL
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The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m above floor level in elevation and at a distance of one (1) metre horizontally from the nearest surface of any equipment / machine, furnished and installed under these specifications, expressed in decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA. 4.23
PACKAGING AND TRANSPORTATION All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till t the time of erection. While packing all the materials, the limitation from the point of view of the sizes of railway wagons available in India should be taken account of. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. The Contractor shall ascertain the availability of Railway wagon sizes from the Indian Railways or any other agency concerned in India well before effecting despatch of equipment. Before despatch it shall be ensured ensured that complete processing and manufacturing of the components is carried out at shop, only restricted by transport limitation, in order to ensure that site works like grinding, welding, cutting & pre-assembly pre assembly to bare minimum. The Employer's Inspector shall have right to insist for completion of works in shops before despatch of materials for transportation.
4.24
ELECTRICAL ENCLOSURE All electrical equipments and devices, including insulation, heating and ventilation devices shall be designed for ambient am temperature (500C) and a maximum relative humidity (75%).
4.25
INSTRUMENTATION AND CONTROL All instrumentation and control systems/ equipment/ devices/ components, furnished under this contract shall be in accordance with the requirements stated herein, unless otherwise specified in the detailed specifications. All instrument scales and charts shall be calibrated and printed in metric units and shall have linear graduation. The ranges shall be selected to have the normal reading at 75% of full scale. ale. All scales and charts shall be calibrated and printed in Metric Units as follows: a) Temperature - Degree centigrade (deg C) b) Pressure - Kilograms per square centimetre (Kg/cm2). Pressure instrument shall have the unit suffixed with 'a' to indicate absolute absolute pressure. If nothing is there, that will mean that the indicated pressure is gauge pressure. c) Draught - Millimetres of water column (mm wc). d) Vacuum - Millimeters of mercury column (mm Hg) or water column (mm Wcl). e) Flow - Tonnes/ hour f) Flow (Liquid) - Tonnes / hour g) Flow base - 760 mm Hg. 15 deg.C h) Density Grams per cubic centimetre.
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All instruments and control devices provided on panels shall be of miniaturized design, suitable for modular flush mounting on panels with front draw out facility and flexible plugin connection at rear. All electronic modules shall have gold plated connector fingers and further all input and output modules shall be short circuit proof. These shall also be tropicalised & components shall be of industrial grade or better. bette 4.26
ELECTRICAL NOISE CONTROL The equipment furnished by the Contractor shall incorporate necessary techniques to eliminate measurement and control problems caused by electrical noise. Areas in Contractor's equipment which are vulnerable to electrical electrical noise shall be hardened to eliminate possible problems. Any additional equipment, services required for effectively eliminating the noise problems shall be included in the proposal. The equipment shall be protected against ESD as per IEC-801IEC 2. Radio Frequency equency interference (RFI) and Electro Magnetic Interference (EMI) protection against hardware damage and control system malmal operations/errors shall be provided for all systems.
4.27
TAPPING POINTS FOR MEASUREMENTS Tapping points shall include probes, wherever wherever applicable, for analytical measurements and sampling. For direct temperature measurement of all working media, one stub with internal threading of approved pattern shall be provided along with suitable plug and washer. The Contractor will be intimated intimated about thread standard to be adopted. The following shall be provided on equipment by the Contractor. The standard which is to be adopted will be intimated to the Contractor. Temperature test pockets with stub and thermo well Pressure test pockets
4.28
ELECTRONIC MODULE/COMPONENT DETAILS The Contractor shall have to furnish all technical details including circuit diagrams, specifications of components, etc., in respect of each and every electronic card/module as employed on the various solid state as well as microprocessor based systems and equipment including conventional instruments, peripherals etc. It is mandatory for the Contractor to identify clearly the custom built ICs used in the package. The Contractor shall also furnish the details of any equivalents uivalents of the same.
4.29
JUNCTION BOXES The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates shall be removable type and made of 3 mm thick sheet steel. The boxes shall be provided with detachable cover or hinged door with captive screws. Top of the box shall be arranged arran to slope towards the rear of the box. The box shall be hot dip galvanized and shall be provided with suitable neoprene gaskets to achieve degree of protection of IPIP-55 as per IS: 2147. Adequate spacing shall be provided to terminate the external cables. cables. The boxes shall be suitable for mounting on various types of steel structures. The terminal blocks provided shall be of 650 V grade, rated for 10 A for control cables. Suitable numbering for terminal blocks
Technical Specifications: Sec-5,General Techn chnical Requirements
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shall be done. In case of junction box for power power cable, the box shall be rated for maximum current carrying capacity. Terminal blocks shall be of one piece, klippon RSF-1 RSF or ELMEX CSLT-1 1 type with insulating barriers. The bidder shall supply the following. S. NO. DESCRIPTION OF MANUALS 1. 2. 3. 4. 5.
6. 7. 8 9 10 11 12 13
NO OF PRINTS (SETS) (SETS)
Drawings "FOR APPROVAL" 4 Drawings "FOR INFORMATION" 4 Drawings "FINAL DRAWING" 10 Drawings "AS BUILT " 10 DATASHEETS,DESIGN CALCULATIONS, etc. and Other type of documents i) For Approval 4 ii) FINAL 10 iii) Analysis reports of equipments/ piping// structures components/ systems employing software packages as detailed in the specifications a) Input 4 b) Output 4 c) Drawings/ Sketches 4 Erection manual "DRAFT" Erection manual nual "FINAL" Operation & Maintenance manual "DRAFT" Operation & Maintenance manual "FINAL" Plant Hand Book "DRAFT" Plant Hand Book "FINAL" Commissioning and Performance Procedure manual "DRAFT" Commissioning and Performance Procedure manual "FINAL"
NO. OF CDROMs
1 CD 1 CD 2 CD-ROMs ROMs 2 CD-ROMs ROMs
1 CD 2 CD-ROMs -
2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS
14
Performance and Functional GURANTEES TEST REPORT
4
2 CD
15 16
Progress Reports Project completion report
4 10
2 CD 2CD ROMS
17
QA programme including Organisation for implementation and QA system manual (with revision-servicing) 1
18
Vendor details in respect of proposed vendors including contractor’s evaluation report.
Technical Specifications: Sec-5,General Techn chnical Requirements
1
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19
20
21 22 23
Manufacturing QPs, Field QPs, Field weldingg schedules and their reference documents like test procedures, WPS, (i) For review/comment 3 (ii) For final approval 4 floppies Welding Manual, Heat Treatment Manuals, Storage & preservation manuals Draft Final 4 sets Monthly Vendor Approval and QP approval status 2 QA Documentation Package for items / equipment manufactured and dispatched to site 2 QA Documentation Package for field activities on equipment / systems at site 2
Technical Specifications: Sec-5,General Techn chnical Requirements
1
set
4 sets 2 CD ROMS 1 CD 1 CD 2 CD ROMS 2 CD ROMS
Page 27 of 27
SECTION 6 ELECTRICS FOR WAGON TIPPLER SYSTEM 1.0 1.1
SPECIAL INSTRUCTIONS TO BIDDERS Inspection of site by Bidder Bidder shall inspect the site and examine and obtain all information required and satisfy himself regarding all matters such as access to site, communication, transport, right of way, the availability of local labour, availability and rates of materials, local working conditions, extreme weather conditions, uncertainty of weather, obstructions and hindrances that may m arise, etc, which may affect the work or cost thereof, before the submission of his tender. Ignorance of site conditions shall not be accepted as basis for any claim for compensation. The submission of tender by Bidder will be construed as evidence that that such an examination was made and any later claims / disputes in regard to price quoted shall not be entertained or considered. Bidder shall also indicate in his bid all the major assumptions including major design assumptions / criteria made by him on which the bid is based.
1.2
Compliance with Specification All equipment and accessories covered under this specification shall conform to the “Technical Specifications” given in this document. In case alternative type of equipment is offered, all technical particulars of equipment offered, number of such equipment supplied in India, reference list of installations where such equipment is in operation as per qualifying requirements, type test certificates cer of their collaborators, type test certificates of indigenously made equipment, extent of import content and availability of spares indigenously, along with any other data for considering the alternative equipment shall be furnished with the offer. offer. The Purchaser, however, reserves the right to accept or reject the proposal without assigning any reason. All equipment shall be suitable for voltage/frequency variations and other data given in Electrical System Design. The contractor shall be responsible for satisfactory working of system with guaranteed parameters. All the major equipment shall be installed, tested and commissioned under supervision of representative of manufacturer of respective equipment.
1.3
Standards and Regulations
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The design, manufacture, performance, testing and installation (including earthing and other essential provisions) of equipment and accessories covered under this specification shall, in general, comply with the latest issue of the following: follow • Applicable Standards and Codes of Practices published by Bureau of Indian Standards. Central Board of Irrigation and Power • • Indian Electricity Act, 2003 • Central Electricity Authority • Indian Electricity Rules • Equipment specific statutory regulations • Indian Factory Act Equipment complying with other recognized Standards such as IEC, BS, VDE, DIN etc. will also be considered if it ensures performance equivalent to or superior to Indian Standards. nd accessories for which Indian Standards are not available, shall be designed, Equipment and manufactured and tested in accordance with the latest issues of recognized Standards such as IEC, BS, VDE, DIN etc. In case of conflict between applicable Standards referred to in this part and technical specifications, the Technical Specifications shall govern to the extent of such difference. 1.4
Make & Interchangeability This specification is issued for procurement of specified equipment and system preferably from indigenous suppliers who may make use of imported systems / sub-systems sub systems / equipment / parts and who have valid collaboration agreement with reputed foreign suppliers suppl with experience in design and supply of similar systems as specified. The Bidder shall furnish division list of supplies from foreign and Indian sources indicating the name of the agency or make against the respective items. It shall be the responsibility responsibility of the successful Bidder to arrange the import license for the imported items offered and to co-ordinate co ordinate the supply of equipment from foreign and Indian sources and execute the contract within the agreed time schedule. The make of major equipment shall shall be limited to preferred makes indicated under ‘List of preferred makes'. Makes of all other equipment and accessories are subject to prior approval by the Purchaser/RITES. Similar equipment and components shall be of same make; equipment of same type and rating shall be interchangeable. The Purchaser has the option of selecting the manufacturer of electrical equipment, instruments and controls and any other specialized items in the interest of standardization and the successful Bidder shall have to supply equipment of particular make, if so required.
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1.5
Safety All equipment shall be complete with approved safety devices wherever a potential hazard exists and with provision for safe access of personnel to and around equipment for operational and maintenance enance functions. The design shall include not only those usually furnished with elements of machinery but also the additional covers, staircases, ladders, etc which are necessary for safe operation of the plant. All danger and caution notice boards shall shall be in Hindi, English and Oriya. The Contractor must take sufficient care in moving his construction plants and equipment from one place to another so that those may not cause any damage to the property of the Purchaser particularly to the overhead and underground cables and other service lines. When the work is carried out at night or in the obscure day light, adequate arrangements for flood lighting in the working area shall be made by the Bidder. Bidde The safely postures/regulations for the prevention of accidents shall be displayed by the Bidder at appropriate places. Notices and warning signs shall be displayed for all sources of dangers. All electrical drives and equipment must be equipped with safety devices. The safety provisions shall conform to the recognized standards, safety codes and statutory regulations. All safety measures as required to be adopted as per the statutory regulations regulati and the safety rules of the plant shall be strictly followed by the Contractor during the execution of the Contract. Adequate number of first aid boxes as defined in the State Factory Rules shall be provided and maintained at all the work sites.
1.6
Coding/Numbering ding/Numbering Scheme A coding scheme for identifying the drawings, plant and equipment, structures, spares and shipping documents shall be adopted by the contractor in a sequential manner.
1.7
Contractor's License The contractor shall possess a valid and and competent contractor's license of specified voltage issued by the electrical licensing authorities of the Govt. of Orissa for carrying out electrical installation work of the type and magnitude covered in this document, in the state of Orissa. The contractor ctor shall also be required to obtain labour license from Statutory Authority.
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Copy of the license shall be made available to the Purchaser/consultant for verifications during the execution of contract. All linemen, wiremen, electricians, supervisors and and engineers engaged by the Bidder or his sub-Bidder Bidder shall possess necessary valid license issued by the statutory authority and the same shall be submitted for verification, if called for. 1.8
Compliance with rules, regulations, and obtaining statutory approval appr All equipment/materials shall be installed in accordance with the requirements of relevant standards, Indian electricity Rules, Indian Electricity Act, 2003 and also the Factory Act. It is the responsibility of the Bidder to see that the electrical installation installation supplied and erected by him shall be to the entire satisfaction of Chief Electrical Inspector, Central Electricity Authority or any other statutory body having jurisdiction in the area and also to the Purchaser/ consultant. btaining all statutory approvals for the installation to be carried out The responsibility for obtaining rests entirely with the contractor. It shall be the responsibility of the contractor to prepare and submit all necessary drawings, calculations, test certificates and relevant details (other than those given by the Purchaser/consultant) to the Electrical Inspector and obtain prior approval for commencing the work and for the complete installation work done. The inspection fee for statutory approvals shall be borne by the bidder.
2.0
SCOPE AND BRIEF DESCRIPTION OF WORK AND ELECTRICAL SYSTEM DESIGN CRITERIA
2.1
General The scope of work includes the basic engineering, detailed design engineering, manufacture or procurement of electrical equipment, shop testing, packing, transportation, loading, delivery at site, unloading, storage at site, handling, erection, pre-commissioning pre commissioning tests and commissioning of all equipment/system including preliminary acceptance test, performance guarantee and post commissioning services, including including insurance cover during transit, storage, erection and commissioning. The job shall be done on turnkey basis. Scope of Bidder shall also include the following: • Supply of commissioning spares • Supply of mandatory spares required for one year normal O&M • Supply of special tools and tackles for the equipment/systems supplied
2.2
Bidder shall provide complete design inputs in form of assignment indicating complete requirements of civil building to accommodate comfortably an electrical substation consisting consistin of electrical equipment under his scope as well as the equipment under scope of the Purchaser, if any meeting all the required statutory clearances. The building shall be finalized and constructed by the bidder Bidder shall also provide the following design design inputs for detailed design and engineering of civil and structural works i.e. foundations, room, etc. The same shall be taken into consideration while designing the civil buildings by the bidder:
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• Static and dynamic loading of the equipment • Clearances,, approach, safety exits required Clearances from all the four sides of the walls shall be maintained, wherever applicable in the electrical premises while considering the design inputs. The civil buildings for the complete WTP substation (including switchgear switchgear room, battery room, transformer rooms, etc), dust suppression MCC room, electric room for WTP, Apron feeder, feeder etc shall be under the scope of work. Electrical sub-station station will be installed in the out door near the wagon tippler station. 2.3
er shall also take into consideration of various aspects like clearances, approach, roads, Bidder safety exits, cable trenches, transmission lines, foundations, floor opening, inserts, underground GI pipes, office premises, etc while finalizing the designing of civil c installations and building within battery limit of the package.
2.4
cope of the Bidder starts from tapping 33KV source including supply of 33KV/415KV Scope transformers and corresponding switchboards, bus ducts and down below all the electrical equipments etc. For WT System Bidder shall include complete electrics including all the equipment/services on turnkey basis as per requirement irrespective of the same ass specified in the specification or not. Separate set of suitable rated 33/0.44 kV transformers, ormers, dedicated MCC for WT System machine, PLC, UPS with sealed maintenance free batteries, VVVF drive control system, junction boxes, other equipment, etc shall be included for smooth operation of wagon tippler system. Air conditioning of control room to be done with suitable capacity by air cooled packaged AC. AC For other LT drives and mechanism, Bidder shall include dedicated MCCs consisting of required number and capacity of outgoing feeders. For dry fog type dust suppression suppression systems of transfer points in junction houses, Bidder shall include a dedicated MCC in pump cum compressor house. For miscellaneous and non-critical non critical loads like power socket cabinets, ventilation, AC power requirement of 33KV switchboard / 415V PCC PCC / transformer marshalling boxes, etc, Bidder shall include a dedicated PDB. For illumination of WT System (Wagon Tippler, Apron feeder) including conveyors and substation, dust suppression room and adjoining areas / sub areas, Bidder shall consider a dedicated LDB and sufficient number of SLDBs. SLDB shall be timer control. Two numbers flood light high mast towers 30m high eachshall shall be included for illumination of WT Area with metal Halide lide Lamps. Illumination of street light and conveyor gallery shall be with LED lamps within a radius of 500m of wagon tippler. tippler
Technical Specification:Sec-6, Electrical
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A separate room shall be provided adjacent to WT control room to house the Dust suppression MCC, Pumps, compressors etc for the DS System by the Bidder. Bidder shall furnish the complete requirements quirements including size, cable trenches/opening, etc. The pressurized ventilation shall be provided by the Bidder in this Dust Suppression Room. The number of MCCs / DBs shall be provided as per requirement by the bidder. Following shall also be included inclu in the Bidder’s scope: • Pressurized ventilation system for the switchgearroom. switchgearroom • Pressurized ventilation system for the Dust Suppression cum MCC room. • Air conditioning of battery and battery charger rooms. • Exhaust fan in the transformer rooms. The bidderr shall supply the PLC for safe operation of WT System. Necessary integration with existing PLC of new coal yard will be scope of tenderer. tender . Design and installation of electrics shall ensure operation of complete integrated electrics of the various drives/mechanism drives/m without any constraint during maintenance. Bidder shall also consider sufficient numbers of local auxiliary PDBs to cater miscellaneous loads of WT System. These PDBs shall be located at various places and exact locations shall be finalized duringg detailed engineering. HT Power cables and LT power/control cables shall be laid in different cable trays. LT power cables and LT control cables shall also be laid in different trays. 24V DC cables shall be laid entirely in different dedicated trays. Cable trays in single tier or in multitier shall be installed in vertical arrangement everywhere to avert coal accumulation and space reduction. Cable trays shall be supplied by the bidder. Power supply of all voltage levels including 415V AC or 220V DC, 24V DC etc, shall be arranged by Bidder himself by providing suitable systems. 24V DC supply shall be through screened cable to be supplied by the Bidder. Only at receiving point of 33KV, control supply of 415V AC and 220V DC shall be made available by the he purchaser. purchaser Following HT cabling shall also be included by the Bidder apart from the above: 1. ACSR conductor for O/H transmission of 33kv line. 2. Cabling required for underground track/road crossings of33 kV System including intake pump well feeder and ashpond feeder. feeder
Standard power and control cables (Trailing Cables) of required sizes in adequate quantum shall be supplied and terminated by the Bidder. Hence, complete HT & LT trailing cables for Wagon Tippler, etc tc shall be supplied and laid by the bidder. Cables used for 24 VDC supply for PLC system shall be laid separately from 230 V AC control cables.
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All cables Power cable, Control Cable, Trailing Cable, instrumentation cables, signal cables, screened cables, es, special cables, fibre optic cables shall be supplied, laid and terminated by the Bidder as per actual site requirement. Cabling shall include laying and termination at both ends, cable trays and cable accessories for the cables to be laid by the Bidder. Bidd Bidder shall consider all required cables for cable engineering, preparation of cable schedule, terminal plans, cable support structure layout, cable layout drawings, etc. All cable trays, accessories, termination kits, glands, lugs, clamps including clamps, etc shall be included in the scope for all the cables (to be supplied by the Successful Bidder) interconnecting both side equipment or one side equipment of the Bidder’s scope. All drives shall be controlled and monitored at existing WT SYSTEM control room from the PLC. Bidder shall include PLC and all the interfacing/ interconnecting cabling and cable trays. All Cables required for this interfacing, shall be supplied and laid by the Bidder. Copper power cables, if required by the bidder, shall also be under scope of supply and laying of the bidder. Ampere meters for all conveyor belts are to be installed at the control room for monitoring the current of each drive. Bidder shall consider numeric PLC and type of Inputs / Outputs (I/Os) required for WT system for smooth and trouble free operation of various drives / mechanism from the WT SYSTEM control room. Sufficient number of I/Os in PLC extension shall be considered as per actual act requirement. Exact number and type of I/Os shall be decided during detailed engineering based on approved schemes. Bidder shall also consider sufficient number of I/Os in PLC control and monitoring for electrical power distribution system for the electrical power distribution system starting from 33KV till the down most voltage level. New PLC of WT shall be interfaced with existing PLC of Coal Handling Plant for operation of BC – 115 and BC – 103. The earthing system shall be provided for complete complete WT SYSTEM plant. The new earthing system shall be connected to the existing earthing system. Bidder shall also consider earthing of following equipment: • 33kv substation equipments. • WT LT distribution transformers – Neutral as well as body earthing • 415 5 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room • Control panel for power distribution equipment at existing WT control room • LT busducts • Charger panels, DCDB, etc at WT substation in switchgear cum MCC room • Underground eart mat.
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Bidder shall consider earthing ring mains at each electrical premise and connect the electrical equipment with the rings. The earthing ring mains shall be connected with underground earthing mats to be provided by the bidder made of 2x40mm dia solid MS rod. Adequate number of risers shall be made available for connection with his earthing ring main. For transformer neutral earthing, bidder shall consider dedicated plate earthing. Lightning protection shall be provided by the bidder for complete WT SYSTEM including tall installations covered under the battery limit. Bidder shall also include complete illumination of the premises under the battery limit and all the above electrical premises coming at WT SYSTEM substation and adjoining areas. conditioning, ventilation and exhaust fans for various rooms / premises of WT SYSTEM Air-conditioning, along with their complete electrics shall be under scope of the Bidder. The battery and battery charger room shall be air-conditioned. Switchgear cum MCC room of WT substation shall have pressurized ventilation. Transformer rooms of the WT substation shall have exhaust fans. fans All interconnection for power, control and instrumentation/signal amongst equipment equipmen supplied by the Bidder shall be under Bidder's scope of work. Similar interconnections including power, control and signal between Purchaser's equipment and Bidder's equipment shall be done by the Bidder. All the cable terminations at both ends, cable trays tr and cable accessories shall be under Bidder's scope. 2.5
Electrical system design criteria a)
General
The design, manufacture, assembly and testing as well as performance of the equipment shall conform to the relevant IS : specifications (latest revision) and other relevant standards. In case IS specifications is not available in respect of certain items, the Bidder may base his proposals on IEC/BS/VDE/DIN recommendations or other reputed national or international standards subject to the approval of the Purchaser/RITES. Purchaser . All equipment supplied and all work done including system design and detailed engineering shall also comply with the statutory requirements of the Government of India and the Government of Orissa.
b)
Climatic Conditions
Electrical Equipment selection and derating shall generally be based on ambient temperature of 50oC. The equipment offered shall be suitable for smooth, efficient and trouble free service in the climate prevailing at Angul. c)
Standard Voltage levels
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Following power utilization standard voltage levels shall be adopted for various systems: 1. Station supply 3. Power supply to PLC extension 4. DC control supply 5. Plant illumination Welding socket / power 6. receptacles Special socket outlets for 7. portable lamps 8. Sockets for electrical tools, etc 9 Emergency illumination d)
33 kV, 3 phase, 3 wire, unearthed system 415 V, 3 phase, 4 wire, solidly earthed 240 V, 1 phase, 2 wire, 50 Hz, A.C. (from UPS) 220 V, 2 wire, unearthed 240 V, 1 phase, 2 wire, 50 Hz, A.C. 415 V, 3 phase, 50 Hz, A.C. outlets 240 V, 1 phase, 2 wire, 50 Hz, A.C. outlets 24 V, 1 phase, 2 wire, 50 Hz, A.C. through suitable transformers 240 V, 1 phase, 2 wire, 50 Hz, with one point earthed 220 V DC
Permissible variations
The system / unit / plant / equipment shall be designed suitably for following variation in voltage and frequency; Voltage +/-10% 10%
Frequency +/-5%
Permissible variation for control and regulation equipment with rated performance and control quality maintained
+/- 10 %
+/-5%
Permissible voltage dip at HT switchgear bus during starting of motor
- 15 %
-
Permissible voltage dip at MCC bus during starting of LT motors
- 15 %
-
Permissible variation with rated performance and control effectiveness maintained
e)
Symmetrical short circuit ratings
The short circuit ratings of all the equipment like MCCs, motors, PDBs / LDBs, cables, power socket & lighting cabinets, etc shall be selected keeping in view the fault level capacities of the Purchaser’s electrical equipment. The three phase symmetrical short circuit rating at 33 kV level shall be 25kA. 25 The three phase symmetrical short circuit rating at 415 V level shall be 50kA. The rated short circuit withstand duration for 33 KV shall be 3 sec, whereas for 415 V system, it shall be 1.0 sec. f)
Criteria for selection of voltage levels for f drive motors
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All AC squirrel cage induction motors shall be fed at 415V V from switchboard through air circuit breakers with numeric type comprehensive compreh motor protection relays via power contactor and overload relay. g)
System Earthing
33kV system is unearthed,, 415V system is solidly earthed. 2.6
ELECTRICAL SYSTEM REQUIREMENTS Minimum number of spare feeders in each of the MCC / PDB / LDB / SLDB shall be 10% subject to minimum one no. of each type and rating in each section. The rating and a type of spare feeder shall be decided during detailed engineering stage. Sizes and requirement of various power and control cables shall be decided and intimated to the Purchaser well in advance to suit the approved scheme/to achieve scheme requirement. requiremen Space heater power supply to the motors shall be fed from the MCC through same cubicle by 415/240 V transformers. Space heaters shall be interlocked with motor main power supply. Bidder to submit a system wise drive list indicating required process interlocks, in permissive conditions etc. with places and mode of control, control system philosophy with provision of various control, indication, measuring devices at various places. The Purchaser/RITES Purchaser shall approve this based on above approved philosophy and and Bidder shall have to provide all equipment / materials and prepare a control scheme/logic diagram which shall be utilized for designing the motor feeders at 33 kV switchboard and 415 V MCC at Bidder’s end. mentioned control philosophy and interlocking logic shall be prepared as per the Above-mentioned technological requirement. Suitable electrics for all the material handling equipment like hoist, etc shall be provided for handling the various drives and mechanism. Warning hooter shall be of brushless type Siren and AC single phase. All actuators shall be of geared motors. Complete 24 V system, wherever required, shall be provided by the bidder. 24 V and 230 V AC shall be taken through separate cables. Screened Screened cables shall be supplied and used for 24 V power supply. All the indication lamps shall be LED based with LVGP (Low Voltage Glow Protection) up to 100 V. All the hoist control panel shall be located at workable height and platform shall be provided forr each hoist at one point for maintenance purpose.
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Ammeter for Wagon Tippler, Apron feeder feede and Conveyors etc. shall also be provided in Control Pane for monitoring of currents. 3.0
PERFORMANCE REQUIREMENT AND GUARANTEE The PG test shall be conducted for overall system of wagon tippler including electrical system and equipments as mentioned elsewhere.
4.0
TECHNICAL SPECIFICATION
4.1
CONTROL & PROTECTION SYSTEM AND LAYOUT CONTROL PHILOSOPHY The control, monitoring, interlocking, annunciation and metering functions of various drives/mechanism shall be performed through PLC at WT SYSTEM control room. All the drives shall also be operated from local control stations for emergency stop as well as for decoupled trial run of motors. ks / alarm, etc shall be provided for various drives/mechanism of cooling Following interlocks water system: • When conveyor will trip, Apron feeder will trip. • When apron feeder trips, Wagon tippler will trip. • When any of the running drive trips, the standby drive shall start automatically. • When any of the running conveyor trips, the preceding/succeeding conveyor shall trip automatically. • A conveyor shall take start only when it’s preceding conveyor starts • Auto-Tripping Tripping of conveyor drives through various mechanism like pull chord, belt sway switch, etc The above interlocks/alarms and control philosophy are minimum and indicative. The detailed requirements for the above shall be finalized during detailed engineering. en Bidder shall furnish details of control, monitoring, interlocking, protection, annunciation and metering system for all drive. Bidder shall use state of art technology while fulfilling the functional requirement of all the equipment for smooth and trouble free operation through PLC. 20 mA range) as per requirement shall be provided to facilitate control Various transducers (4-20 and monitoring from PLC. Required transducers and wirings to hook up all analog and digital inputs / outputs to / from PLC shall be included in the scope. Interlocking arrangement shall also be furnished to take care of all the approved logic schemes. Bidder shall provide necessary wiring, control and required items to achieve the approved logic / scheme. Selecting local local / remote switch of local control station in local position shall carry out local mode operation of the drives for test/trial etc. Permissive
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conditions for start and tripping of various drives shall be provided as per approved logic diagrams. ed hardwired control panel / desk shall also be provided by the bidder at WT control A dedicated room to control and monitor electrical power distribution system. Controls of all equipments of wagon tippler including conveyor’s all interlocks shall be PLC based. The PLC system shall be latest version having dual redundant processor with HMI based control station. There shall be two HMI control system with one operating station and other an engineering station. The system shall be designed with 10% extra input/output provision. p Input/output of PLC(analog & digital) shall have at least 10% extra channel wired up to TBs TB in the panels. A portable programming station (Laptop) with all the ladder logic/ programming/software shall be provided for engineering and troubleshooting troubleshooti functions. The system shall be capable of communicating with the existing PLC system of the CHP(The existing PLC is of GE Fanuc makemake Model 90-30,CPU-370). 370). The vendor shall be responsible for communicating and displaying the important parameters of wagon wagon tippler PLC system to the existing CHP PLC through optical fibre cable. All electrical power distribution system shall be controled and monitored through PLC. PROTECTION SYSTEM Protections for the different electrical equipment are enlisted below: motor comprehensive omprehensive numeric motor protection shall be provided in the For Protection of LTT motor, switchboard. Laying of control and power cables including supply and laying of signal cables from motors to switchboard shall be in the scope of Bidder. ensive numeric motor protection including but not limited to the following: Comprehensive • Instantaneous over current protection • Differential protection (for rating above 1000 kW) • Instantaneous time over current protection in two phases and definite time delayed over current urrent alarm on the third phase • Negative phase sequence protection • Thermal overload taking -ve and +ve phase sequence into account • Earth fault • Locked rotor protection • Winding temp monitoring and alarm for rating beyond 1000 kW • Under voltage protection protectio Microprocessor based numeric motor protection relay shall also have following facilities: • Communication facility with open protocol like IEC/Modbus. • Relay should store last five fault records (minimum) with date and time stamping. • Relay should have no. o. of start menu for start inhibition. • Relay should have facility for displaying three phase and neutral current Technical Specification:Sec-6, Electrical
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• Relay should have heavy duty tripping contact which will be used for breaker tripping • Battery backup facilities The Motor Protection Relays shall also have the following additional features: • Fault recording facility • Password protection • Local/remote communication facility with open protocol • Minimum 4 nos. BI and 4 nos. BO Protection of LT motor (less than 75 kW) Motors below 75 kW shall be fed from MCC through MCCB with power contactor and overload relay. Motors of 5 kW and above but below 75 kW, shall have fed through MCCBs (for short circuit protection), numeric motor protection relay like MPR-300 MPR 300 or equivalent equivalen (for overload and other motor protection) and power contactors. For motor below 5 kW, MPCBs may be considered in place of MCCBs. Single phasing protection shall also be provided in the MCC modules. METERING Following metering shall be provided in various MCC/DBs; 415 V MCC 1. 415 V INCOMER (EACH) • AMMETER (DIGITAL TYPE) • VOLTMETER • kWH METER 2. BUS COUPLER • AMMETER 3. OUTGOING • AMMETER (DIGITAL TYPE) MOTOR FEEDER (EACH) PDB 1. 415 V INCOMER COMER (EACH)
4.2
• AMMETER (DIGITAL TYPE) • VOLTMETER 2. OUTGOING (EACH) • AMMETER (DIGITAL TYPE) LT MOTOR CONTROL CENTRE (LT MCC) Constructional Features Fully drawout type with modules having service, test and isolated positions. Floor mounting, free standing with base channel 50 mm high for fixing on the inserts on the floor. MCC shall be single front, totally enclosed, dust and vermin proof. All the module of the MCCs shall be spacious to facilitate maintenance of equipment inside the module. Pollution degree applicable shall be pollution degree 4 as per IS-13947 IS 13947 (Pt-I), (Pt 1993.
Technical Specification:Sec-6, Electrical
Page 13 of 97
Incomer and bus coupler panels MCC incomers and bus couplers shall have Air circuit breakers. Incomers and bus couplers shall be rated for at least 125% of maximum demand demand taking into account the spare feeders and shall be suitable for the specified fault level. Incomers and bus coupler shall be electrically interlocked to prevent parallel operation. However, a definite delay defeat Interlock switch shall be provided to facilitate parallel operation. Auto changeover facility shall also be provided between the two incomers and bus coupler. Feeder Modules Feeders for motors of 75 kW and above shall be fully drawout type air circuit breakers (ACBs) with numeric type comprehensive mprehensive motor protection relays. Other motor feeders shall be consisting of MCCB, contactor, overload relay as main power components to ensure type 2 protection. The short circuit release of MCCBs shall be suitably selected to the applications concerned. At least 10% spare feeders (minimum one spare feeder of each type and rating bus sectionsection wise) shall be provided. Ammeters with selector switches shall be provided for all continuous / intermittent running motors beyond 15 kW rated drives. d terminations Busbars and Busbars and connection shall be of high conductivity aluminium/aluminium alloy of suitable hardness and purity complying with as per IS-5082-1981. IS 1981. Busbars shall be insulated by colour coded heat shrinkable sleeves. Busbars shall be rated for the nominal current rating of incoming breaker and for the full short-circuit circuit rating. Earth bus shall run throughout the length of MCC at bottom . Control bus shall be provided in the bus bar chamber isolated with main bus in all the MCCs. Similarly power and control terminations shall be in separate chambers in the MCCs. Cable alleyy shall have sufficient space for maintenance and minimum width of cable alley all shall be 300 mm. Shrouding/isolation shall be provided for outgoing power terminations in the th cable alleys. ys. Modules of MCCs shall be spacious for easy maintenance of the various equipment inside. Short circuit strength Rated short time withstand current shall not be less than 50 kA for 1 second. Rated peak withstand current not less than 2.1 times the specified short circuit level. Air circuit breaker (ACB)
Technical Specification:Sec-6, Electrical
Page 14 of 97
Air break, drawout type conforming to IS 13947 (1993) and symmetrical symmetrical breaking capacity not less than 50 kA for 1 second shall be provided. Service short circuit breaking capacity (Ics) shall be 100% of rated ultimate short circuit breaking capacity (Icu). Performance category of the MCC shall be B. ACB used for incomer incomer & bus coupler should have numerical feeder protection relay. Motor operated mechanism shall be applicable with air circuit breakers. Spring charged stored energy mechanism shall be there to ensure high speed closing and tripping independent of the operating perating forces. Electrical anti pumping and trip free feature shall also be provided. Spring charging universal motor suitable for rated control voltage (220 DC). The closing coil and trip coil shall be suitable to DC operation. Closing and tripping of ACB shall be by closing coil (operating range 85% to 110% of rated voltage) and tripping by trip coil (operating range 70% to 110% of rated voltage) respectively. Built-in in direct acting type microprocessor based numerical releases for short circuit, over current and earth fault shall be provided. Auto changeover shall be done through under voltage relays and check synchronization relay with time delay. All the relays shall be microprocessor based numerical relays.
Motor protection moulded case circuit breaker (MCCB) The characteristic shall match the motor duty application. Rated ultimate short circuit breaking capacity (Icu) shall be 50 kA. Ratings selected shall be at least 125% of the full load current of the motor. otor. For small rating drives such as valves, Siemens 3UV13 type (or equivalent) or motor protection circuit breaker (MPCB) shall be used. Utilisation category shall be A. Magnetic contactors Pick up shall be positively at voltage between 85% to 110% of rated value. For frequently reversing drives, AC 3 rating selected shall be 50% higher than full load current of the motor at the specified duty cycle shall be provided. For reversible drives, mechanically as well as electrically interlocked contactors shall sh be used. Thermal overload relay Thermal overload relay shall be triple pole, ambient temperature compensated, inverse time lag, hand reset type, bimetallic with adjustable setting and built in single phase protection. The relay shall be able to withstand prospective short circuit-current circuit without damage or injurious heating till the motor protection MCCB clears the fault. Tripping indication and reset push button operable from outside shall be provided. Push Buttons / Indicating Lamps / Indicating instruments
Technical Specification:Sec-6, Electrical
Page 15 of 97
Push buttons shall be spring ng return, push to actuate type and their contacts shall be suitable to carry and break 240 V AC, 10 A and 220 V DC, 1 A. Indicating lamps shall be LED LVGP (Low Voltage Glow Protection up to 100V) type. Standard colours shall be applicable for push buttonss and for indicating lamps. Indicating instruments shall be flush mounting, square dial with 900 scale with zero adjusting device for external operation. Accuracy class shall be 1.0 or better. KWh meter shall also be provided with incomers. MCC shall havee run / start, stop, tripped, and ready to start push button cum indication lamp for motor feeders. Current transformers The thermal and dynamic stability current for CTs and CT ratio shall be as per requirement. Protection and measuring current transformer transformer shall be bar primary/ window type with 1A secondary. Burden of CTs shall be as required by the associated measuring equipment. Potential transformers Potential transformers shall be provided on incomers as well as on buses and shall be in same circuit rcuit breaker cubicle. 415 V side of PTs shall have fuses. Accuracy class 1.0 shall be used. VA burden shall be selected based on meters and relays connected with the PT. Control transformer Control transformers shall be dry type 415V/240V, primary taps at +2.5 %, +5 % and shall be mounted in drawout trolley if outgoing feeders are in drawout execution. Control supply shall have supervision facility, alarm shall be provided for non availability availability of any one of the control supply. Automatic/manual changeover facility shall also be provided. Auto-changeover Auto shall be blocked if power supply to respective section is not available. For capacity consideration of control transformers, each shall be capable capable to meet 100 % load including spare feeders and 10 % cushion for future and 15 VA for each module for remote aux. relays and indication lamps. Separate DC and AC control (3 ph & neutral) copper busbars shall be considered for each MCC. From AC control control bus, motor space heater supply shall be tapped with suitable control and interlocking arrangement. 220V DC Control supply 220V DC supply is required for electrically controlled ACBs. For two sections, two DC buses shall be there. In bus coupler panel, manual switch shall be there for changeover of one supply to other section. Non-availability availability of DC supply shall be annunciated in MCC or nearby control room. Internal Control Wiring and external Terminations
Technical Specification:Sec-6, Electrical
Page 16 of 97
Internal control wiring shall be by 1100V V grade PVC insulated, single core stranded copper conductor of minimum cross section 2.5 sq.mm. for CTs and space heater circuits and 1.5 sq.mm for other circuits. For CT secondary wiring, disconnecting type terminal blocks (CAD type) shall be considered.. For external terminations,, DIN rail mounting type bakelite type terminal blocks shall be used complete with insulated barriers, stud type terminals, washers, nuts and lock nuts and identification strips. Power and control terminals segregated. Other accessories Following items shall be provided for the MCCs under the scope of the Bidder: Breaker lifting/handling trolley (for ACBs) : 1 No. per MCC Room Breaker racking handle (for ACBs) : 4 Nos. per MCC Room Panel key (if applicable) : 5 Nos. per MCC Room Selection of power components & wiring for continuous duty cage motor drives is given below: Motor Rating at S1 Duty (KW ) Up to 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 125 135 160
Minimum size for internal power connections Copper Aluminium flat wire (mm x mm )** (sq.mm)
Minimu m rating of MCCB
Minimum rating of contactor (AMPS) AC3 duty
* * *
25 40 40
4 4 6
-
4x 2.5(copper) 4x 2.5(copper) 4x6
* * * * * * * * * * * * * *
40 63 63 63 100 100 160 160 200 400 400 400 400 400
6 10 16 16 25 35 50 70 95
12 x 2 12 x 2 12 x 2 15 x 3 15 x 3 20 x 3 20 x 5 20 x 5 30 x 5 40 x 5 40 x 5 40 x 5
4 x 16 4 x 16 3.5 x 35 3.5 x 35 3.5 x 70 3.5 x 70 3.5 x 95 3.5 x 120 3.5 x 185 3.5 x 185 2(3.5 x 120) 2(3.5 x 120) 2(3.5 x 120) 2(3.5 x 185)
Minimum size of power cable Aluminium (sq.mm)
*Minimum rating of MCCB shall be selected to achieve type ‘2' protection.
Technical Specification:Sec-6, Electrical
Page 17 of 97
** Copper flat of equivalent size can be used instead of aluminium flat. NOTES : Overload relay shall be selected based on actual full load current and starting time. GENERAL TECHNICAL PARTICULARS OF MCC GENERAL 1. System 2. Type 3. Pollution degree 4. Creepage distance 5. Enclosure 6. Mounting
: 415V, 3 phase, 4 wire, 50 Hz. Solidly earthed neutral : Indoor type, cubicle construction, free standing :4 : As per IS-13947 (1993), Part-I : IP54 : I/C & B/C in single tier and O/G in multi-tier tier arrangement execution 7. Neutral earthing : Effectively earthed 8. Control supply : 240V AC / 220 DC for ACB 9. Short time rating : 50 kA for 1 sec 10. Autochangeover required? :Yes 11. Delay drop off required? uired? :Yes 12. Control supply : 220 V DC for ACB, 240V AC/220 DC for spring charge motor and 240 V AC for MCCB, etc. AIR CIRCUIT BREAKER : Indoor 1. Service 2. Type : Air – break 3. Insulation level : 6 kV (1.2x50 micro Sec) Impulse withstand withsta 4. Utilization Category :B 5. Operating mechanism : Stored energy type I. Closing : Motor wound spring operated II. Opening : Shunt trip coil III. Latching : Mechanically and electrically trip free arrangement 6. Auxiliary Voltage : DC (85% - 110%) I. Closing II. Tripping : DC (70% - 110%) III. Spring charging : 240V + 10% AC or DC motor IV. Space heater & Lamp : 240V + 10% AC 50 Hz 7. No. of poles of C.B :3 CURRENT TRANSFORMERS 1. Type : Resin cast, window type 2. Rated voltage : 415 V +10% 3. C.T. secondary : 1 Amp rating 4. Accuracy i. Protection : 5P10 or better for protection ii. Metering : Class - 1 Technical Specification:Sec-6, Electrical
Page 18 of 97
POTENTIAL TRANSFORMERS 1. Type : Cast Resin 2. Primary/secondary voltage ratio
:
415V 3
110V 3
3. Method of connection :Star/Star connection 4. Rated voltage : 1.2 continuous, 1.9 for 30 Sec factor 5. Class of insulation : Class E or better CONTROL TRANSFORMER 1. Type : Dry cast resin, class B or better 2. Voltage ratio : 415V/240V 3. Rated burden : As per requirement (Minimum 1.5 kVA) 4. Quantity : 2 nos. per board and minimum capacity shall be 1 kVA MOULDED CASE CIRCUIT BREAKER 1. Type : Air break (Motor duty) 2. Rated service : 415 V +/+/ 10% voltage 3. Utilization Category : A 4. Protection : Type `2 to the contactor CONTACTORS :3 1. No. poles 2. Rated service : 415 V + 10% voltage 3. Control circuit : 240V +10% 1ph, 50Hz +5% 4. Utilisation category : AC23A for uni-directional uni motors 5. Limits of operation : 85% to 110% i. Closing (pick-up) ii. Dropout : Shall not be higher than 75% RELAYS/RELEASE 1. Relay type 2. Release type
: Numeric : Microprocessor based.
THERMAL OVERLOAD RELAYS 1. Type : Ambient temperature compensated bimetal operated hand reset type (direct or C.T. operated) 2. Hand resetting : To be provided at the front of the panel feature 3. Single phasing protection : Built in 4.3
CABLE AND CABLE ACCESSORIES
TYPES OF CABLES
Technical Specification:Sec-6, Electrical
Page 19 of 97
All cables viz.power power and control cables, trailing cables, signal, instrumentation, screened, fire optics, copper power cables and special purpose cables required for applications concerned and for satisfactory operation of the all the drives at Wagon Tippler plant shall be in the scope of the Bidder. All power cables(XLPE) cables should be FRLS (Fire Retardant low sulphur) type (inner & outer sheath) and shall have round armouring. armouring Bidder shall include all the cable accessories in his scope of supply as as well as installation as per actual requirement at site. Trailing Cables All the trailing cables shall be 4 core XLPE. The cable for application in 33 KV supply system shall conform to IS:7098(Part (Part-2) 2) 1985 and for low and medium voltage including 1100v shall conform to IS: 7098(part I)),1988. HT trailing cables shall be 33 KV (UE) heavy duty power cable 4 core, flexible. The detailed specification for the HT trailing cables required shall be furnished furnished by the Bidder along with the tender. 1.1 kV grade flexible trailing cable shall be of heavy duty type having tinned annealed high conductivity flexible copper conductors, butyl rubber or ethylene propylene (EPR) insulation and CSP or PCP sheathing. The conductor shall conform to IS:8130 - 1984 and insulation and sheathing shall be as per IS:6380 - 1984. For high temperature zone and side-arm-charger side the insulation shall be of silicone rubber. For all the cabling, Bidder shall include laying laying including all the GI prefabricated cable trays/hot dip galvanized perforated trays and other cable accessories like cable termination/jointing kits, glands, cable identification tags, connectors, ferrules, clamps, etc
HT Cable End Termination & Straight through jointing kits All high voltage cable terminations shall meet the test procedures and requirements stipulated in IEEE 48-1990 as class-II termination. Heat shrinkable type of cable termination and joints shall be used for HT cables in indoor i and outdoor applications as specified. The stress control and grading wherever necessary shall be by means of semi conducting heat shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces shall be achieved by using ng hot melted sealants or adhesives.
Technical Specification:Sec-6, Electrical
Page 20 of 97
Where such sealants or adhesives shall be exposed to high electrical stress, same shall be track resistant type. Straight through joints and end sealing termination kits of 33 KV (UE) grade cross-linked cross polyethylene cables shall be of well tried out design compatible for XLPE insulation. The joints/ends sealing kits shall be of heat shrinkable type and shall be complete with stress grading material, protective and lug sealing sleeves, self tightening earthing clamp, slide angle sleeve etc. Outdoor termination shall have necessary skirting over protective sleeving to increase the creepage distance and the sleeves shall ensure total protection against ingress of moisture. Straight through joints shall feature moisture proof proof environmental seal, mechanical protection and impact resistance envelope around the joined cables. The end termination and straight through joints shall conform to the relevant standards. The complete termination / joint kits shall be of reliable and field proven design having been fully type tested and relevant type test reports shall be furnished. In addition the termination and joint shall be tested for various accelerated aging tests such as thermal aging, weathering etc. to have long and trouble trouble free service. Necessary type test certificates for aging tests shall also be furnished. Following type of cable termination and joints shall be used for HT cables in indoor and outdoor applications: 1. 2. 3.
Tapex type Heat shrinkable type Pre moulded push on type
Tapex type system The stress grading material shall be wrapped around the cable core, over lapping the edge of the outer conducting layer. The tape layer shall fuse together to form a compact rubber body around the stress grading ng material and cable core and thereby exert an active pressure on cable. This system shall be used for straight through joint only. Heat Shrinkable type system The stress control and grading wherever necessary shall be by means of semi-conducting semi heat shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces shall be achieved by using hot melted sealants or adhesives. Where such sealents or adhesives shall be exposed to high electrical stress, same shall be track resistant type. moulded Push On type system Pre-moulded
Technical Specification:Sec-6, Electrical
Page 21 of 97
Premoulded refers to moulded Ethylene Propylene Diene monomer rubber components. Sealing between the pre--moulded moulded push on material and cable surface shall be achieved by semi conducting pad which has cold flow f properties. Cable trays All the cable trays shall be prefabricated hot dip galvanised sheet steel trays. Prefabricated GI ladder type / perforated type cable racks/trays shall be used for laying of cables in cable trenches, cable spreader floors, cable cellers, through piping and while routing cables along technological structures etc. The factory made system of cable trays shall be complete in all respects with all standard accessories like reducers, bends, tees, risers etc. and shall be suitable for bolted type assembly at site so as to avoid any welding. The GI ladder type factory fabricated cable trays made made from 2.5 mm thick hot welded steel sheets grade ‘o’ shall be provided as per IS : 2062. Hot dip galvanizing of 86 micron thick as per IS-2629, IS-4759 and IS- 209. Trays shall be of standard length of 3 M / 2.5 M with max deflection not exceeding 1/400 of span with sufficient load bearing capacity. Sheet steel thickness shall be minimum 2.5 mm. Rung hall be provided at every 250 mm. At one meter interval two rungs shall be provided side by side to facilitate clamping. Beside, Bidder shall also provide suitable pre-fabricated pre fabricated bends of cable trays at all the bending points as per actual site requirement. Horizontal tees and 900 bends shall be provided for each size of cable trays as per actual requirement at site. Lugs/connectors hall be made with aluminium / tinned copper crimped type solderless lugs Cable termination shall of approved make for all aluminium conductor and stud type terminals. The lugs shall be tinned copper compression type. Glands Cable glands to be supplied shall be nickel plated brass brass double compression type. Glands for classified hazardous areas shall be certified by CMRS and approved by CCE, Nagpur. Cable glands for terminating PVC insulated armoured/unarmoured cables (as applicable) shall be made of brass and shall be of double compression type with necessary provision for armour earthing.
Cable clamps All cables shall be clamped with GI (minimum size of 25x3mm) / Al (minimum size of 25x4) clamps and single core cables shall be clamped with trefoil clamps made of non-magnetic non materials.
Technical Specification:Sec-6, Electrical
Page 22 of 97
Specifications for miscellaneous materials Cable identification Cable tags shall be of 2 mm thick, 20 mm wide aluminium strap of suitable length to contain cable number as per cable schedule. Ferrules Ferrules shall be approved interlocked type & size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected, for ease in identification and maintenance. LT BUS DUCTS
Electrical design Bus duct shall be suitable for 33KV/415 415 V, 3 phase, 50 Hz. neutral solidly grounded system and shall be covered with canopy if required to be installed outdoors. outdoors. Rated short time withstand current not less than the system short circuit level specified for 1 sec for 415V. Rated peak withstand current not less than 2.1 times the system short circuit level. Rated continuous current shall be as per requirement while in enclosure and at specified ambient temperature with maximum temperature temperature of bus bars limited to 85˚C. 85 Neutral bus in LT with rating not less than half the rating of phase bus. The bus duct shall be rectangular, non-segregated non segregated phase, totally enclosed type.
Insulation level Rate insulation voltage, one minute PF withstand withstand voltage & impulse withstand voltage shall be as specified in technical particulars.
Clearance in air (minimum) Clearance shall meet the minimum requirement specified in the technical particulars.
Short circuit strength Rated short time withstand current not less than the system short circuit level specified for 1 sec for 415V. Rated peak withstand current not less than 2.1 times the system short circuit level.
Rate current Rated continuous current as specified while in enclosure and at specified ambient temperature with maximum temperature of bus bars limited to 85˚C. 85 Neutral bus in LT with rating not less than half the rating of phase bus.
Type test certificates Tenderer shall have type test certificates for similar bus ducts (same voltage level and same or higher current rating/fault level)
Technical Specification:Sec-6, Electrical
Page 23 of 97
Construction details Degree of protection for enclosure IP 52 or better for indoor installation. Enclosure material:: The minimum thickness shall be 2.5 mm. Tender shall include enclosure with the thickness required red for the shape and mechanical/ electrical strength point of view. Aluminium enclosure shall be provided for rating equal or more than 3000A. MS enclosure may be provided for LT bus ducts of rating less than 3000A. Provision shall also be provided for draining moisture. Maximum temperature of enclosure under rated operating conditions limited to 70˚C. 70 Rubber bellows shall be provided at transformer end to take care of vibration. GI supporting structures, wherever required, shall be provided with necessary hardwares. In horizontal run of more than 10 mtr of bus ducts expansion joint with copper flexibles shall be provided at every 10 mtr interval. Maximum temperature of enclosure under rated operating conditions limited to 70˚C. 70 Bolted covers with gaskets shall shall be provided for easy inspection and access to insulators and bus bar joints. Gasketted (Neoprene) connections shall be provided between adjacent sections of metallic enclosure. Tinned copper flexible shall be considered for connection of bus ducts at transformer end as well as PCC end. Rubber bellows at transformer end shall be provided to take care of vibration. Seal off bushing and frames complete with bolts. Provision shall be provided for draining the moisture. Provision shall be provided for mounting the bus ducts on brackets. The bus duct shall include straight run, 90 degree bend, Phase crossover chamber, transformer end chamber, tinned copper flexible, wall frame assembly, rubber bellows and other accessories as per the requirements.]
Busbars rs and connections. Bus bar material shall be EC grade aluminium alloy equivalent to E91E WP conforming to IS 5082-1981. Final operating temperature of both bus bars and joints under continuous operation in enclosure limited to 85˚C ˚C by thermometer method. While designing the bus duct, site condition and solar radiation shall be taken care of. Bus bar arrangement shall be as per IS 5578-1991. 5578 1991. Phase identification shall be by colour at ends and at regular intervals. Busbar joints shall be of bolted type, cadmium cadmium plated with zinc bichromated high tensile steel bolts, nuts and spring washers and coated with oxide inhibiting grease prior to jointing. Copper flexible busbars shall be tinned. Copper flexible connections shall be provided for termination on equipment as well as on expansion joints. Bimetallic joints /strips shall be provided for jointing between dissimilar metals (if required). Bus bar support insulators of non-hygroscopic non hygroscopic material having impact and di-electrical di strength with an anti-trackin tracking contour. Bus duct of 3000 A and above rating shall be interleaved type. Bus conductor shall be given a coat of black mat point.
Protective earthing Double earthing shall be provided for enclosure of bus ducts. Technical Specification:Sec-6, Electrical
Page 24 of 97
Two numbers 50 x 6 mm GI flat earth buses shall shall be provided running separately throughout the length of the bus duct, positively connected to the enclosure body of the bus ducts. Provision shall be there at each end of bus duct for terminating external earth conductor. Surface treatment Two Coats of synthetic enamel paint for indoor application shall be provided. Various standard procedures shall be followed in this regard for a quality work. Shade of paint Interior
:
Black/white/light yellow
Exterior
:
As per technical particulars
Technical particulars of LT busducts Applicable standard
:
IS - 8623
Rated system voltage & frequency
:
415V, 50 Hz
Maximum ambient temperature
:
50˚C
System earthing
:
Solidly grounded
System short circuit level(kA rms)
:
50 KA
Maximum voltage at which bus duct can operate : continuously Location of bus duct :
500 V
Type of bus duct
:
Non Phase segregated
Material of main busbar
:
Aluminium Alloy
Rated continuous current
:
As specified
Earth bus material
:
Aluminium
Bus duct support structure required
:`
To be provided
Rated continuous current
:
As specified
Rated short time withstand capacity
:
50 kA
Rated short time withstand duration
:
1 sec
Technical Specification:Sec-6, Electrical
Indoor
Page 25 of 97
Insulation level
Insulation class
:
1.1 kV
1 minute dry power frequency withstand
:
2.5 kV
1 minute wet power frequency withstand
:
2.5 kV
Support insulator
:
Type
:
Maximum distance between supports
:
Non: hygroscopic SMC moulded/FRP To be worked out based on short circuit calculation.
Clearance
Phase to Phase
:
25.4m
Phase to earth
:
19.0m
Material
:
Degree of protection (Minimum )
:
Thickness of material
:
AI (for >/= 3000 A) / MS (For < 3000A) IP52 – Indoor IP55-Outdoor Outdoor 2.5 mm (minimum)
Sea- Off bushing with wall frame (for wall crossing)
:
Only wall frame required
Silica gel breather
:
Required
Space heaters
:
Required
Maximum temp allowed at max. ambient temp
:
Bus conductor
:
85˚C
Bus enclosure and support structure
:
70˚C
Enclosure
Accessories
Technical Specification:Sec-6, Electrical
Page 26 of 97
Paint shade
:
Phase crossover chamber/section
:
Interior: yellow
Black/white/light
Exterior: Approved One set in one of the bus duct portion of each PCC/board.
ERECTION, INSTALLATION ACCESSORIES All erection & installation accessories required for erection/installation of equipment are included in the scope of the tenderer. All the accessories and other erection materials required to complete the erection job in all respect shall be considered as part of the tenderer’s scope. Safety insulating mats of minimum thickness of 2 to 3 mm and of suitable voltage grade in front of all the PCCs/board and control panels shall be provided by the tenderer.
4.4
ELECTRIC MOTORS General All motors shall generally conform to IS 325 and CBIP publication No. 140. Motors shall run continuously at rated output with + 5 % variation in frequency and + 10 % variation in voltage and + 10 % combined ned variation of frequency and voltage (absolute sum). Motor shall not stall due to momentary drop in voltage up to 70 % of rated value and shall run satisfactorily for five minutes at a supply voltage of 75 % of rated value. The limiting value of voltage at rated frequency under which motor will successfully start and accelerate to rated speed with load shall be assumed to be a constant value of 80 % rated voltage throughout the starting period. All motors shall be supplied with foundation bolts (if applicable), applicable), drain holes with plugs. Motors shall be designed for 50oC ambient temperature. Motors supplied shall be complete with required double compression cable glands, crimp type cable lugs and first filling of lubrication, name plate, etc. Lifting facility facility to be provided for all HT motors and big size LT motors. Guards shall be provided to prevent accidental touch for couplings and for free shaft ends shall be provided. Degree of protection for motor and bearings shall be IP-55 IP 55 for indoor and IP55 with wit rain canopy and weather proof construction for outdoor. Motor shall be suitable to withstand at least three successive starts from system cold condition and two starts from hot condition at normal system voltage and frequency. The drive motor shall havee at least 15 % margin over the maximum power requirement of the driven equipment after considering all losses, de-rating de rating due to temperature and specific site and operating conditions.
Technical Specification:Sec-6, Electrical
Page 27 of 97
The motor may be subjected to sudden application of 150% rated voltage voltage during bus transfer, due to phase difference between the incoming voltage and motor residual voltage. Motor handling facility and canopy Handling facility and space shall be provided for all the LT motors. Mono rail shall be provided and shall be extended up to open maintenance space for each of the LT L motors. Canopies made of GI sheet of minimum thickness of 2 mm shall be provided to each of the LT motors located outdoor. All motors, in general, including conveyor motors shall be 4 pole construction, hence speed of maximum 1500 rpm. However, motors for travel drives of yard machines shall be of 6 pole construction, hence speed of 1000 rpm. rpm LOW VOLTAGE INDUCTION MOTORS Frame sizes shall be as per IEC. Casing feet shall be integral with the motor body. For motor of rating up to 5 kW, ball bearings shall be used for both DE & NDE end. For ratings above 5 kW the DE end shall be provided with ball/roller bearing and NDE end shall be provided with ball bearing. Bearings shall be suitable for running of motor in either direction. Motors 110 kW and above shall be provided with bearing bearing temperature indicators. Explosion proof/increased safety design for explosion hazardous areas as per requirement. Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable by 4x90o Cooling of motors shall be of TEFC TEFC (IC0141) design. Ventilation shall be effective irrespective of direction of rotation. Motors shall be dynamically balanced. Vibration intensity shall be limited as per IS 12075 (1987). Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from motor body. Starting current shall be less than or equal to six times the rated current with IS tolerance. Motors shall have class ' F' insulation with temperature limited to class ‘B’. Permissible temperature shall be limited to 120oC in case of class 'B' insulation and 130oC in case of class F insulation as measured by resistance method. Class H insulation shall be considered in specific cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as measured byy resistance method. Space heaters shall be provided for all motors rated above 30kW. Adequate handling space shall be provided for all the big LT motors. HIGH VOLTAGE MOTORS
Technical Specification:Sec-6, Electrical
Page 28 of 97
Degree of protection for motor and bearings shall be IP-55 IP 55 for indoor use and a IP-55 with removable rain canopy for outdoor use. Vibration monitor with contacts shall be provided at the DE end of motor bearing for motors of ratings 1000 kW and above. On line vibration measurements shall be provided for larger and critical motors. All motors shall be provided with Bearing (DE & NDE) temperature detectors and 6 nos. stator winding temperature detectors, RTDs for monitoring alarm and trip conditions. Temperature shall be displayed on VDU's. RTD's shall be of PT100 type and suitable for digital scanner or PLC input requirement. igital type bearing temperature indicator for all motors shall be provided for local Digital measurement with adjustable alarm contacts. Each terminal box shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.25 0.25 sec and shall have pressure relief device. Terminal boxes shall be suitable for termination of FRLS, XLPE cables with cable end seals. Separate terminal boxes shall be provided for space heaters, RTDs for winding/ bearings temperatures, vibration monitors etc. All terminal boxes shall be provided with two earthing studs for termination of protective earth conductor. Box covers shall be provided with handle to facilitate easy removal. Low kW range machines may be of TEFC (IC0141) design. For higher rating, rating, type of cooling shall be CACA (IC0151). General accessories like flow switches, space heater, terminal boxes, drain plug, dowel pipe cable lugs, glands clamp etc. shall be provided. Vibration intensity shall be limited to values as stipulated in the the IS. Motor shall be designed to withstand the vibration produced by the driven equipment. Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from the motor body. Electrical design shall be same as in case of low voltage induction motors motors except the following: All motors shall have class F insulation but with total permissible temperature limited to 1300C (as measured by resistance method). Starting current of the drives shall be limited to six times of full load current. Motors of rating 1000 kW and above shall be provided with differential protection. Matching CT and cabling up to switchgear shall be provided by the Bidder. Motors shall be capable of withstanding locked rotor current at 110 % rated voltage for at least 2.5 sec (for or motors having staring time up to 20 sec) or 5 sec (for motors having staring time more than 20 sec) longer up to than starting time under rated load condition at 80 % voltage. If above condition is not possible then, centrifugal type speed switch to be provided
Technical Specification:Sec-6, Electrical
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which has to be connected to the motor protection relay. Speed switch shall be capable to withstand 120 % of the overspeed in either direction. Insulation of motors shall be designed conforming to IEC 34-15/ 34 15/ 1990. Gland plate for single core cable shall be non-magnetic magnetic type. All motors shall have individual dedicated handling and lifting facilities preferably by dedicated electric hoist. 4.5
POWER DISTRIBUTION BOARD /AUXILIARY POWER DISTRIBUTION BOARD POWER DISTRIBUTION BOARD PDB shall be suitable for 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec) indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof, draw-out draw (incomer & bus coupler) / fixed (outgoing), fully compartmentalized compartmentalized and extensible on both sides, IP54 type enclosure. Shall have isolated busbar chamber for main busbar at the top, running throughout the length of the board. Chamber shall have removable cover. Busbars shall have same cross section throughout the length . Rating of the neutral busbar shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the length of the panel. Shall have Moulded case circuit breaker (MCCB) triple pole, air break type with independent manual quick make and quick break type. MCCB shall be capable of breaking rated current at 0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system. Generally PDB will have following feeder arrangement. However, details of feeders e.g no. type and capacity, etc shall be finalized during detailed engineering: Incomer Outgoings
: :
ACB of 630A (or as per requirement) MCCBs of 400/250/125A/63A/16A (or as per requirement)
Number and capacity of PDB given in the enclosed Single Line Diagram is minimum and indicative. Bidder shall provide as per actual load requirement and same shall be finalized during detailed engineering. AUXILIARY POWER DISTRIBUTION BOARD Aux. PDBs shall be suitable for 415V, 3 phase, 4 wire, wire, 250A, 50 kA (short time rating for 1 sec.) indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof, non-drawout, drawout, fully compartmentalized and extensible on both sides, IP54 type enclosure.
Technical Specification:Sec-6, Electrical
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The other technical particulars particulars of aux. PDBs shall be similar to PDB. The tentative feeder arrangement shall be as follows. However, details of feeders e.g no. type and capacity, etc shall be finalized during detailed engineering: Incomer : MCCB of 250A (or as per requirement) Outgoings : MCCBs of 125A/63A/16A (or as per requirement) 4.6
LOAD ISOLATOR WITH EARTH SWITCH 33 KV ON-LOAD Technical features • Triple pole air break, fault make load break type. • Independent manual, quick make, quick break type • Mechanical trip device • Mechanical “ON”- “OFF” indicator • Suitable to connect cables on incoming and outgoing side. • Shall have 3 NO and 3 NC aux. contacts. • Earthing switch shall be provided on transformer side having rating same as that of main switch. outdo kiosk type with IP-55 55 protection along with a • Totally enclosed, floor mounted, outdoor canopy • Shall have padlocking facility • Panel door shall be mechanically interlocked so that isolator cannot be closed on open position of door and door cannot be opened on close position of isolator. • Earthing switch shall be interlocked with isolator blades to prevent simultaneous closing of both. • Isolator shall be interlocked with Purchasers upstream breaker. Technical particulars :33kV 1. System voltage 2. System earthing : Resistance earthed 3. Type : Air break, fault make & load break type 4. Nos. of poles : Three 5. Continuous current : As per requirement 6. carrying capacity 7. S/c withstand capacity : 25KA for 3 sec/43.7 kA for 3 sec. 8. Pf withstand voltage : 75/20 kV 9. Impulse withstand voltage : 170/60 kV 10. Termination : To accept cables of required size 11. Incomer 12. Outgoing : To accept cables of required size
4.7
OIL IMMERSED TYPE) HT/LT TRANSFORMERS (OIL 4.7.1 Design Design shall be generally as per IS 1886. Transformer shall be suitable for rated frequency 50 Hz, -5%, 5%, +5%. Insulation level shall be designed according to the voltages specified below: Description
Technical Specification:Sec-6, Electrical
33/.415 kV
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Capacity Nominal voltage (kV) Max system voltage (kV) Power frequency withstand voltage (kV) System earthing No. of phases Frequency Impulse test withstand voltage (kV) Short time current rating (for all current carrying parts) Fault level (3 phase symmetrical) Type of Cooling Connection HV winding Connection LV winding Connection Symbol
33 35 75 Low resistance earthed 3 50 Hz 170 25 kA for 3 sec 25kA ONAN DELTA STAR Dyn 11
HT/LT transformers shall be of the latest design, oil immersed type as per IS : 1886 and testing as per IS 2026 part I.. All dry type air natural transformers shall be suitable for indoor use line up with power control centre as unit type. Bidder shall ensure that manufacturer shall have his own in-house in house core cutting facilities on CNC machines. ken to make enclosed equipment proof against entry of rats, lizards and Special care shall be taken other creeping reptiles which may create electrical shortshort circuits inside live equipment. The design of each transformer shall be such that the risk of accidental short-circuits short due to reptiles or vermin shall be obviated. The transformer shall be of cast resin type. The tap changing arrangement shall be of removable link type. Each transformer shall be suitable for operation at full rated power on all tappings without exceeding the temperature rise of 800C over the ambient of 50oC. Minimum class of Insulation shall be F. The transformers shall be designed to be capable of withstanding, without injury, the thermal and mechanical effects of short-circuits short between phases or between n phase and earth at the terminals of any winding with full voltage applied across the other winding. All transformers shall be capable of withstanding specified through fault current for minimum of 2 seconds as per IS: 2026 (Part-1). The transformers shall all be designed to suppress harmonic currents, especially the third and fifth, so as to eliminate distortion in the wave form and consequent additional insulation Technical Specification:Sec-6, Electrical
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stress, noise on communication system and undesirable circulating currents between the neutrals ls at different transformer stations. The Transformers shall operate with minimum noise and vibration. The cores, protective housings and other structural parts shall be properly constructed and windings properly braced so that the mechanical vibrations are kept to the minimum, thus reducing the noise. To this effect, the laminations shall also be bonded together with appropriate resin. The core-coil core assembly shall also be fixed in such a manner that no shifting or deformations occur during shipment or installation. Each transformer shall be designed for minimum no-load no load and load losses within the economic limit. All electrical connections and contacts shall be of ample section for carrying the rated current without excessive heating. all be of stainless steel, brass, gunmetal or other suitable material to prevent All mechanism shall sticking due to rust or correction. If any temporary fitting is fixed to the protective housing of the transformer for transporting / handling purpose, these shall be identical identica as well as instructions and illustrated drawings shall be furnished to facilitate their removal at site after erection. 4.7.2
Core
The framework, clamping arrangement and general structure of the cores of each transformer shall be of robust construction and shall be capable of withstanding any shock to which they may be subjected during transport, installation and operation. The assembled core shall be securely clamped on the limbs and the yoke to build up a rigid structure. The clamping pressure sure shall be uniform over the whole of the core and so adjusted as to minimize noise and vibration in the core when the transformer is in operation. The framework and the core bolts shall be effectively insulated from the core so as to reduce the eddy-currents eddy rents to the minimum. The magnetic circuit shall be built of high quality, low loss, non-ageing. non ageing. Cold rolled, grain oriented, silicon steel laminations (CRGO Prime Grade) having excellent magnetic properties and specially suitable as core material. Laminations Laminations shall be insulated from each other with material having high inter-lamination inter lamination insulation resistance and rust inhibiting property and also capable of withstanding stress and mechanical vibration. Necessary cooling ducts shall be provided for heat dissipation dissipation from the core so that the anticipated maximum hot spot temperature in the core shall not be injurious to any material used in the core assembly. clamping frame shall be provided with lifting eyes having ample strength to lift the The core-clamping complete te core and winding assembly. Suitable provision shall be made in the dry type transformers for effective core earthing. Technical Specification:Sec-6, Electrical
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4.7.3
Winding
The coils used for transformer winding shall be made of insulated, continuous and smooth electrolytic copper conductors of high conductivity and of 99.9% purity. Similar coils shall be connected by accessible joints brazed or welded and finished smooth. No corona discharge shall result on the winding during induced voltage test as specified in applicable standard. The insulating materials for dry type transformers shall be of type not inferior to Class “F”. All insulating materials shall be of proven nature nature and shall be suitable for the suitable for the limits indicated in the applicable standards as well as the maximum possible winding temperature and shall not deteriorate when the transformer is operated continuously at its specified rating at the specified specif ambient temperature. coil insulation shall be so designed that the dielectric stress is The inter-turn and inter--coil uniformly distributed throughout the winding under all operating conditions. The windings shall be dry cast resin type. er windings shall be designed for basic Impulse insulation level not lower than The transformer those specified above. 4.7.4
Protective Housing for Dry type Transformer
Dry type transformer shall be provided with suitable protective sheet steel housing, with minimum IP P 23 degree of protection for the enclosure. The housing shall have ventilation louvers provided with wire mesh screens and shall be supplied with suitable lifting lugs. Safety limit switches shall be provided and wired in such a way that the incoming supply supp may be disconnected whenever any one of the sides of the enclosures are opened with the transformer in energized condition. Sufficient precautions shall be taken so that doors are closed fully. Door locks shall be provided and keys shall be universal type. 4.7.5
Circuit Links Off-Circuit
circuit tapping links shall be provided on the HV side with appropriate register plate to The off-circuit show the link location. The links shall be provided with a separate door for access. The door shall be provided with appropriate safely limit switches which will trip the transformer HV / LV sides in open condition. 4.7.6
Cooling
or dry type transformers shall have Air-Natural Air Natural (AN) cooling. The cooling system for 4.7.7
Neutral Bushing Current Transformers
Technical Specification:Sec-6, Electrical
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CTs for back up earth fault (51N) as well as for restricted earth fault (64) shall be provided on the neutral end. Neutral bushing CT shall be removable removable at site without opening transformer tank cover/active part. Secondary leads of 4 sq.mm shall be brought to a weatherproof terminal box and from there to the marshalling box. Neutral bushing CTs of suitable ratio, class and adequate burden shall be provided by the Bidder to cater to the requirement of all standard protection associated with the transformer of this capacity. CTs for REF shall be PS class. 4.7.8
Marshalling Box
Enclosure mounted marshalling box to be supplied with all controls instruments, protection, accessories & fitting as required for the transformer and its associated ancillaries. The box shall be made of 2 mm sheet steel with IP 54 degree of protection. heet steel marshalling box of dust-proof dust proof design shall be provided to accommodate Sheet temperature measurement as well as control system, as may be necessary. The box shall be mounted on the transformer enclosure and shall be provided with internal lighting, space spa heater and thermostat with their controls accessible from outside. The box shall be provided with suitable hinged steel doors at the front and all equipment shall be so placed as to accessible from the front. Provision shall be made for padlocking the doors. Suitable glazed windows shall be provided at appropriate positions to give an unrestricted view of the temperature indicators etc, without opening the door. All initiating tiating “contacts” of shall be wired up to the terminal block in the box. All control wiring shall be with 1.1kV grade stranded PVC insulated armoured copper cable of 2.5 sq.mm. Terminal blocks shall have 20% spare capacity. The external connections between between the apparatus on the transformer and the marshalling box shall be done with suitable heat resisting copper conductor cables of core size not less than 2.5 sq. mm. The cables required to connect the marshalling box and transformer accessories shall be adequately dequately protected against mechanical damage. There shall be no joints or tappings between two terminations of any cable. Not more than two terminations shall be made at any one terminal. All terminations at various devices and terminal blocks shall be provided pr with plastic ferrules having engraved numbers. All terminals and links shall be so arranged as to facilitate easy checking and testing of relays, instruments etc. Provision shall be made for termination of power cables as well as multi-core multi control cables in the marshalling box. The control circuit terminal blocks provided for external cable connections shall be provided with screw type terminals and shall be complete with terminal screws, links, cable carries etc, Each terminal block shall have 20% 20% spare terminals and all wiring shall be such that it is easily identifiable and accessible for maintenance.
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All devices, wires and terminal blocks within the marshalling box shall be clearly identified by symbols corresponding to those used on relevant schematic or wiring diagrams. Enclosure class of marshalling box shall be IP-55. IP Terminal Arrangement HV/LV terminals shall be suitable for cables considered. 4.7.9
Transformer Fittings & accessories
Each transformer shall be fitted with all standard standard and special fittings and accessories and shall include but not be limited to the following: • Inspection covers. • Off circuit links in the primary for voltage variations. • Rating, diagram and tap connection plates. • Terminal marking plate • Two nos. earthingg terminals with lugs. • Winding temperature detectors with microprocessor based Temperature scanners with digital read out and requisite set of remote signaling contact for alarming/tripping operation. bi directional rollers with locking and bolting devices. • Under carriage with bi-directional • Marshalling box complete with all instruments, accessories and fittings as required for the transformer. • Off load tap changers with position indicators and padlocking faciliy • Neutral eutral bushing CTs with terminal arrangement • HV cable box with disconnecting chamber and supporting arrangement • LV side flanges suitable to receive busducts • Jacking pads • Haulage lugs required • Flat base, foundation bolts and clamps and other accessories as required 4.7.10
Details of Fittings
Requisite number of Resistance type temperature detectors shall beprovided with solid state type temperature signaliser for dry type transformer. The temperature signaliser shall be provided with two sets of contacts, one one for alarm and the other for circuit-breaker circuit trip. The signaliser shall be provided with digital read out for the temperature being measured and for the zone where the current measurement. Two nos. earthing terminals of adequate mechanical and electrical capacity shall be provided. Separate earthing terminals shall also be provided on the enclosure, marshaling box and terminal boxes. Rating and diagram plates shall be provided as per adopted adopted standards for each transformer. Lifting lugs and hauling holes as required shall be provided for the transformer as well as for the enclosure.
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Suitable under-carriage carriage fitted with flat rollers shall be provided. The rollers shall have adequate mechanical ical strength and shall be so designed that the transformer shall roll without undue effort after it has remained immobile for a long period. The edges of rollers shall be duly rounded off to permit skidding of transformer on flat surface. (33KV/ 4.7.11 Technical Particulars of HT Transformers (33KV/440V) 1.0 1.1 1.2 1.3 1.4 1.5 1.6 2.0 2.1 2.2 2.3 2.4
General Make Type Service Duty Degree of Protection Reference Standard Rating Rated output Quantity Type of cooling Rated voltage Volt H. V. L. V. 2.5 No. of phases 2.6 Rated Frequency Hz 2.7 Vector group reference 2.8 Connection H. V. L. V. LVn 2.9 Insulation H. V. L. V. 2.10 Insulation level kVp/kV H. V. L. V. 3.0 Temperature 3.1 Reference ambient temp. 3.2 Temp. rise over reference ambient a) Top Oil measured by b) In winding by 4.0 Tappings 4.1 Type 4.2 Taps 4.3 Taps provided on HV winding 5.0 Method of earthing Technical Specification:Sec-6, Electrical
: : : : : :
Reputed Make Two winding Outdoor Continuous IP:55 IS/IEC Equiv
: : : : : : : : :
As per load calculation 2 nos ONAN
: : :
Delta Star Grounded through NGR
: :
Uniform Uniform
: : : :
75/28 40/10
: :
500C Thermometer 550C Resistance
: : : :
33kv 440V 3 50 Dyn11
500C
Off circuit Tap Changer (OCTC) ±10% in steps of 2.5% Yes Neutral Grounding Resistor Page 37 of 97
6.0 6.1 6.2 6.3 6.4 6.5 6.6 7.0 7.1 7.2 8.0 9.0 10.0 10.1 10.2 11.0
Neutral grounding Resistor Rated current : Less than 100A for 10 seconds Application : Grounding through Resistor Service : Outdoor Resistor material & connection : Punched stainless steel grid element type Maximum allowable temperature rise : As per Standards over ambient 500C Enclosure degree of protection : IP - 55 System Fault Level H. V. : 25kA L. V. : 50kA Conductor material : Electrolytic grade copper Creepage distance mm/KV : 3lmm/kV Terminal connections H. V. : Segregated phase bus duct/Cable L. V. : Segregated phase bus duct/Cable Marshalling box Degree of protection : IP:55
Power frequency to withstand voltage of 33 KV system should be 75KV.Impulse KV.Impulse test voltage should be 170KV for system voltage of 33 KV. 4.7.12 Technical Particulars of Dry type transformers (LT) : As per requirement : AN : Indoor : 33/0.440kV : As per IS : Delta/star : Dyn11 : HV : 33KV cable LV : Cable 9. Tap changer : OFTC 10.Range of tap changer : +5% in 5 steps @2.5% 11. Short circuit level : 25 kA (33kV) for 3 sec 12. Earthing system (33 kV) : Low Resistance earthed 13. Earthing system (415 V) : Solidly earthed 14. Bushing CTs : On neutral 15. Ratio of neutral al bushing CTs : As required for Standby E/F Restricted E/F 16. Impulse test withstand voltage (HT/LT) : As per IS/IEC 17. Power frequency rated short duration : As per IS/IEC withstand voltage (HT/LT) 18. Temp. rise above 500C : 800C 19. Overload capacity : As per ANSI standard 20. Auxiliary supply voltage : 240V AC 1. Rated capacity 2. Cooling 3. Duty 4. Voltage ratio (HV/LV) 5. Impedance 6. Winding connection 7. Vector group 8. Termination
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21. Suitable for parallel operation 4.8
: Yes
VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE Basic design particulars All VVVF Converters shall have Digital Control Technology with vector less control. VVVF shall communicate to basic automation system. Type of connection • Three phase frequency converters with rectification and inversion i.e. variable voltage and variable frequency output with current source / voltage source (PWM) inverters. • Line reactors for harmonic and noise suppression • Suitable for 415 V , 3 phase ,50 Hz , 4wire neutral earthed system Overload capacity following 100% load & to meet the drive overload • 150% of the rated current for 1 minutes following capacity. • Efficiency more than 95% at full load • Suitable to withstand vibrations more than 0.59. • Output frequency : 5-50 Hz (Constant torque) 50-100 Hz (Constant power) • Ramp rate: Linear acceleration and deceleration deceleration adjustable independently. Power components The main power components of the VVVF equipment shall have the following incoming AC side: Matching input power transformer / reactor • • AC line surge suppression network. • ACB/MCCB • Line contactors Inverter Equipment Converter –Inverter • Thyristor converter bridge for AC/DC • DC link circuit with reactor/capacitor • Inverter bridge for DC/AC • PLC to take care of interlocking and sequencing etc. • Mimic panel where drive is HT Load side • Filter network up transformer, as required • Step-up • Isolator and over-load over relay for each motor. By-pass Arrangement
Technical Specification:Sec-6, Electrical
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•
By-pass pass arrangement shall be provided to operate the motor in case of failure in frequency converter.
Thyristor converter Minimum ratings of thyristor cells • • PIV rating : 2.5 times the peak value of line voltage • dv/dt rating : 200V/microsecond for voltage control and 1000V/microsecond for inverter control. • di/dt rating : 100A/ microsecond. Protective features AC line surge suppression network net • • Under voltage in supply network • Phase sequence protection and monitoring • RC snubber network across each thyristor cell • Thyristor fuse failure • Under voltage in Dc line • Over voltage in Dc line • Over speed monitor • Over load • Earth fault • Instantaneous over current • Transformer fault • Cooling fan failure – Stall monitor for motor Alarms Above condition shall be annunciated. Following warning signals shall also be provided as minimum in addition to above. te vibration) as applicable • Motor fault (winding / bearing temperature, • Loss of frequency command • Meters, Switches, Lamps Following shall be provided as minimum meters: • Input volt meter and ammeter with selector switches • Output voltmeter and ammeter with selector switches. • Output frequency ncy meter • Selector switches, pushbuttons, and lamps as required. • kW meter for drive ratings above 200 kW Regulation and controls Control facilities shall include following but not limited to: • Reference speed setter • Ramp generator • Speed feed back • Current feed back • Trigger module • Pulse transformers • Logic control module Technical Specification:Sec-6, Electrical
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• Sequence module • Zero speed/over speed monitor as applicable • V/f control • Current limiter • Counter current/ regenerative braking unit as applicable • active electronic components used shall be of industrial grade hermetically sealed • Regulated power supply for reference setting: Voltage variation of (+/-)) 0.1 % with an input variation of +10% - 15% Steady state regulation of (+/-)0.25% (+/ % guaranteed against 100 to 200 % load disturbance and + 3%, -6% 6% input supply frequency variation. • Facility to accept speed reference from computer/ programmable controller Construction features • Floor mounted, free standing • Dust and vermin proof • Sheet steel clad • Minimum 2.5 mm thick for panels. • Minimum 2.0 mm thick for doors and side covers. • Suitable to withstand vibrations to be encountered in steel plant application. • Cubicles with illumination lamps, door switches, space heaters and adequate sockets for soldering. • All control blocks plug –in-type with necessary test sockets. • Units shall be self contained and serviceable. Enclosure and Ventilation • Enclosure conforming to IP-52 IP or more with weather proof enclosures • Units shall be provided with cooling fans and louvers at the bottom sides. All louvers shall have fine mesh behind them. • Ventilation through individual ventilation ducts, from bottom not acceptable. 4.9
RELAY PANELS Relay panels (RP) housing aux. contactors, timers, relays, etc. shall be provided for equipment control, sequential control, monitoring, safety alarm signals, annunciation signals, interlocking of drives ,signal exchange, interface with future system etc. shall be provided. Constructional features of R.P. shall be similar to MCC. At least 10 % spare auxiliary contactors, timers &relays shall be provided in the relay panel whose contacts and coils shall be wired up to terminals.10 terminals. % spare terminals shall also als be provided. 10 % of auxiliary contactors, timer and relays shall be provided as spares which will be wired upto terminals.
4.10
PROGRAMMABLE LOGIC CONTROLLERS (PLC) Power supply system
Technical Specification:Sec-6, Electrical
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Input power supply shall be fed through UPS system. However, PLC shall be capable of withstanding power supply from electrical feeder. Alternate source of power supply arrangement or second UPS shall be provided to take care of the situation when the original UPS fails. in power supply units Built-in • Suitable for thee power supply system as specified above. • Independent units for the following: • CPU and associated electronic units i) sensing the status of input devices ii) driving outputs if outputs are relays iii) Insulation level 2.5 kV for 1 minute. • Protection againstt surge protection & short circuit • Electronic over current protection with feedback feature. Central processor unit in type • Modular and plug-in • 32 bit microprocessor based • Scan time 2 m sec per one K Words of instructions or better • Provision to latch desired outputs. • The processor shall have in-built in built provision for examining input conditions, compare, compute, logical, conversion from/ to BCD, bit manipulation, block memory manipulation, diagnostic, shift, sequencing, conditional jumping, subroutine instructions. • In-built built PID instruction shall be preferred over separate PID hardware Module. • Timer & counter modules shall be provided wherever required. Memory units Modular and plug-in type • Word length 32 bit as per CPU • Expandable in blocks of 4K Words • Minimum size 16K Words • EPROM/ RAM with battery back-up back • Back-up up battery shall be as follows: i) Rechargeable Ni-Cd Cd batteries with necessary charging circuit, Lithium or any other internationally acceptable type. ii) Able to retain memory for a minimum of 1 year with no power applied to the controller. Input units • High density (32/16 Channels), modular and plug-in plug type • Insulation level of 1.5 kV • Input interrogation voltage 24V DC • Discrete input units shalll have the following: i) Filter to take care of contact bounce ii) Opto-isolation isolation to isolate the input device from the controller Technical Specification:Sec-6, Electrical
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iii) LED status indication iv) BCD input units suitable for four digit input • Analog input units shall be as follows: i) Suitable for 4-20 20 mA / 0-10V 0 / +/-10V inputs ii) With necessary A/D converter • Pulse/ frequency input module shall have range up to 50 kHz. For very high frequency applications, the range shall be up to 1 MHz. Output units plug type • High Density (32/16 Channel), modular and plug-in • Discrete output units shall be as follows: i) Opto-isolated isolated outputs with insulation level of 1.5 kV ii) Rated for 24V DC, 2A • Power devices like contactor or odd voltage actuating device shall be b actuated through relays • LED status indication • BCD output units shall be as follows: i) Suitable for four digit output ii) Rated to drive seven segment LED displays iii) With insulation level of 1.5 kV • Analog outputs shall be as follows i) Suitable for 4-20mA/ 20mA/ 0-10V/ 0 +/-10V 10V outputs capable of driving Digital / Analog Panel Meters ii) With necessary D/A converters iii) With insulation level of 1.5 kV iv) Any special requirement to control field devices shall be met by using separate interface modules PC based programming unit: • PC used for Programming Terminal shall be commercial grade and latest available in the Suitable for developing programs in ladder diagram/ block diagram or statement form • With facility for loading the program from floppy • The terminal shall be capable of developing multiple programs offline without connecting to the programmable controller. Self diagnostic features • Parity errors, cycle errors and under voltage • Failure in central processor unit, memory and power supply. sup • Indication of type of failure • Automatic turning OFF of all outputs or optionally holding of all outputs in their last state on failure detection. Additional features • Fully pre-programmed • Connection of field devices with input units through throu ordinary multi--core copper control cables of 1.5 sq. mm size, upto a length of 500 m. Technical Specification:Sec-6, Electrical
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• Connection of remote input/ output units to programmable controller through remote I/O units, wherever substantial saving in cabling is envisaged. • Serial interface, ce, RS232C and better shall be provided • High speed communication among PLC and operator consoles/ display units shall be provided through ethernet • Latest appropriate model of HP Inkjet Printer to get hard copy of the program dump/ data logging / alarm m logging / event logging / data trending etc. [Printer covered also under “Programming Unit”. Only one printer shall be supplied.] Special features • Switch to disable all outputs of the controller during start-up/ start up/ debugging • Fuse failure indication for outputs Mounted spares • Min of 30 % of I/O modules used of each input & output type (with at least one module of each type) shall be offered as unused spare for each I/O rack. Minimum of 30% I/O rack slots shall be kept reserved rved for future expansion. • 30 % spare memory capacity shall be provided Constructional features • Unitised construction • Floor mounted, free standing and indoor type • Bottom cable entry • Sheet steel clad • Dust and vermin proof • Suitable to withstand vibrations as per application • All modules plug-in in type Enclosure 42 class • Conforming to IP-42 • Conforming to IP-54 54 class for remote I/O cubicles located in shops/ bays. Miscellaneous air ditioned enclosure, shall be suitable for • Programmable controllers, even if housed in air-conditioned normal industrial environment and ambient temperature upto 500C. A suitable fan with inlet air filter shall be provided at the top of each PLC panel for proper air circulation. • Dual redundant processor shall be envisaged. Redundancy shall be provided in such a way that in case of failure of the main processor, the standby shall takeover automatically. The changeover shall be bump less and the system shall be fail proof. Redundancy Redundan shall be provided for complete processor system including CPU, Memory, Power supply and Communication sub system. • Failure of a single processor shall not affect the system. • In case of failure of complete processor system, outputs shall take fail safe state st automatically. • It shall be possible to generate the first out alarm contact by the PLC in case where a group of parameters are likely to trip a system.
Technical Specification:Sec-6, Electrical
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• •
• • • • 4.11
The communication subsystem between PLC processor and I/O subsystem shall be dual redundant. munication subsystem between processor subsystem and PLC console shall be dual The communication redundant, consisting of two separate communication interfaces and two buses, each one configured in redundant mode. No hardwired alarm system is required. All the alarms are to be displayed in OWS of PLC with multi tone buzzer and with alarm history provision. The software provided at the time of supply should be of latest version. Necessary license to be provided along with the software. The OS (Operator Station) desk and operator operator chair to be supplied by the bidder. UNINTERRUPTIBLE POWER SYSTEM (UPS) General System Description The required kVA, 50 Hz, single phase UPS system shall provide continuously operating uninterrupted power supply to critical AC loads such PLC, PLC, instrumentation, etc. The capacity of UPS shall be suitable to feed power requirement of the PLC which shall control and monitor all the drives/mechanism of proposed additional coal handling system. The UPS system shall include but not necessarily limited to the following equipment: • One 100% rated battery bank • One set of Float Charger (FC) and one set of Float cum Boost Charger (FCBC) complete with associated incoming AC switchgear. • Two nos. 100% capacity inverter banks. • One no. DC switchgear, connecting connecting above and also inverter banks stated above • One no. 3 phase to 1 phase transformer and associated AC switchgear, 230V, 1 phase voltage stabilizer and backup source static switch. • One no. 240 V UPS ACDB • One no. four way manual bypass switch • Static switches • All inter connecting cables/wiring with connection accessories and other required items to make the system complete. Mode of Operation Normal Mode During the normal operation the UPS shall be used to provide power to the critical loads. loa The primary AC source shall be used to supply power to the rectifier charger. Two (2) no. chargers shall feed regulated DC power to their individual inverter banks and simultaneously float charge the backup batteries. Emergency Mode
Technical Specification:Sec-6, Electrical
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Upon failure of primary AC source supplying three phase power to the battery chargers, the input power to the inverters shall be supplied from the back up batteries. When the AC power is restored, input power for the inverter and power for recharging the battery b shall automatically be supplied from the rectifier charger. The batteries shall supply the inverter whenever the chargers are unable to supply the sudden load demand or their response to the load change is slow. The output of the UPS shall feed all all the essential loads through the ACDB. The connection from the UPS to ACDB shall be through a switch and fast acting semiconductor fuses, trip fuses and micro switch with alarm contacts. The feeders shall be designed by the bidder to suit the load requirements. Battery Charger Two (2) nos. each of 100% capacity, battery chargers shall be provided for each UPS system. These chargers shall be of static type and shall be provided with suitable transformer and full wave, SCR type rectifiers. Chargers shall share automatically the load during parallel operation of the inverter system and shall maintain output voltage within plus or minus one percent of the nominal value from no load to full load. Suitable ripple filtering circuits shall be provided to give a smooth DC output. The ripple content shall be limited to less than +5% on resistive load. The rectifier charger shall have float, equalising and boost charging facility as well as furnish the inverter input current. In the `Boost' mode, the ‘boost' chargers chargers shall recharge the completely discharged battery to full capacity in eight (8) hours. In charger system, all the standard protection, metering and static annunciation shall be provided. Static Inverters The two (2) nos. 100% capacity, (IGBT) required required kVA inverters shall be static type consisting of SCR type inverter, static filters, integrated control modules including necessary oscillators, voltage regulators, current limiting and surge suppression networks. In addition, the inverters shall have ve features of soft start, wave shaping, transient recovery etc. Any other equipment required for normal operation of the inverter shall be included irrespective of whether specified or not. The output from the inverter shall be 240V AC, sine wave 1 phase. phase. The output of the UPS shall be distributed to the essential loads through the AC switchgear. The connection from the UPS to the AC switchgear shall be through a switch and a quick acting fuse. The feeders shall be designed by the bidder to suit the load requirements.
Technical Specification:Sec-6, Electrical
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Static Transfer Switches The static transfer switches shall use SCRs and other static devices, for automatic transfer of load from the Normal source to the Alternate source. The continuous capacity of each static switch shall be equal to the full load capacity of one inverter. Maximum transfer time including sensing shall not be more than 1/4 cycle. The transition shall be "make before break" in both directions. The static switch shall be provided with fuses in both `normal' and `alternate' `alternat power source. Provision for annunciation of failure of fuse or failure of alternate source shall be made. The switch shall be provided with surge suppression networks and shall also be rated to withstand transient voltages upto 150% of rated voltage. The The short time rating of the switch shall be 150% of the rated full load current for two (2) minutes. Three phase/single phase Transformer and voltage stabilizer The transformer connection shall preferably be of Le Blanc type with delta connected winding on the three phase side or of open delta connection type. Other alternatives shall also be considered, provided the connection has minimum unbalance on the primary side. The transformer shall be encapsulated in Class B insulation. The transformer shall be adequately rated for the duty involved. The actual value may be slightly increased to take care of any losses in the static voltage stabiliser. The voltage stabiliser shall employ silicon solid state circuitry and shall maintain the specified output voltage for 0 to 100% load, with maximum input voltage variation as specified. specified Manual Bypass Switch The manual bypass switch shall be a four (4) position switch. switch. It shall be used to isolate a static switch from its load and alternate power supply and to take it out of service without power interruption to the load. It shall be ‘make before break’ type contacts, so that power supply to the loads is continuous during during switch operations. It shall be capable of carrying rated continuous full load inverter current. Fault Diagonistic Unit Unit Fault diagonistic unit shall be provided to supervise UPS operation. Facility to take print out and recording of important parameters parameters shall be provided. All the alarms shall be interfaced with DDCMIS. Battery DC battery shall be VRLA, sealed maintenance free type. Battery capacity should be 500Amp Hr with float charger of 110 Amps. Float cum boost charger should be 110Amps also. Battery shall be located in the battery room. Battery shall be suitable to maintain the power supply for at least 60 minutes (battery back time) in the event of mains failure.
Technical Specification:Sec-6, Electrical
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Necessary distribution board for distribution of power from UPS output to t individual consumers. Permissible variations for mains power supply system shall be as follows: : + 10 % , -15 % Voltage Frequency : As per IS Harmonic distortion : < 5% Output of the uninterruptable power supply system while delivering a load of its rated capacity (P.F of load shall not effect its output) shall have following variations; Voltage regulation :1% (For 0-100% load) Frequency : (+/-) 0.5% (For 0-100% load) Efficiency :Above 80% 100% to 0% and 0% to 100% load : Volt dip +10% Enclosure and ventilation Enclosure conforming to IP-41 IP 41 class. Units shall be provided with cooling fans and louvers at the bottom sides. Individual ventilation ducts for each each unit shall be provided. Distribution Board The DB shall have two buses, main and standby and shall be protected by semiconductor fuses with fuse monitoring device, bus healthy lamps, voltmeters and ammeters. Each load shall be fed by two independent feeders. Isolating and buscoupling switches shall be provided. The enclosure sheet steel thickness shall be 2.0 mm. with cold rolled sheets and 2.5 mm for hot rolled sheets and enclosure class protection shall be IP-54. IP TECHNICAL PARTICULARS 1. Application 2. Capacity 3. Degree of protection 4. Cable entry 5. Input Supply Voltage
: Uninterruptible Power supply for PLC and and other essential loads : 200 % of PLC load : IP 54 : Bottom : 415V+/415V+/ 10%, 3 phase 4 wire, 50 Hz +/- 5%
Batteries 1. Type 2. Application 3. Number of cells in each bank in series 4. Ambient temperature 5. D.C. nominal system voltage 6. Ampere hour capacity 7. Charging method proposed 8. Emergency load duration
Technical Specification:Sec-6, Electrical
: VRLA, SMF : UPS System : As per requirement : Min.temp. :5.0 deg.C Max.temp. :50 deg. C : Suitable to inverter system : Bidder to furnish along with calculations cal : . Float and boost : 60 Minutes (battery back up time)
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9. Continuous load/duration
: As per requirement
Battery chargers : 2 nos. (1 FC + 1 FCBC) 1. Number required 2. Type : Static 3. Method of charging : Float and boost charge type 4. DC system voltage : To suit the system 5. Automatic voltage regulator required(AVR) : Yes 6. Regulation with AVR : +/-1% 7. Permissible harmonics at rated continuous load : +/-2% +/ 8. D.C. load requirement a) Momentary : As per requirement b) Emergency : As per requirement c) Continuous : As per requirement 9. Maximum time for boost charging : 8 Hours Inverters 1. Type 2. Suitable for parallel oper 3. Service 4. Output rating 5. Output Voltage 6. Phase 7. Frequency 8. Total harmonic content any single harmonic. 9. Duty 10. Overload capacity 11. Efficiency 12. Cooling 13. Synchronization with source
: Continuous. : 125% for 15 minute at 0.8 p.f : Not less than 80% at rated load : Natural air cooled : Yes
Static transfer switch 1. Capacity Continuous 2. Type 3. Voltage 4. Frequency 5. Transfer time
: Make and carry F.L. current of inverter at 0.8 p.f. : Make before break : 240V, single phase : 50 Hz : 1/4 cycle maximum
Manual bypass switch 1. Capacity Continuous 2. Type 3. No. of positions 4. Short time rating 5. Transfer Technical Specification:Sec-6, Electrical
: Static : suitable for parallel operation : Indoor : As required : 240 V A.C. : Single phase : 50 Hz : 5% RMS maximum not more than 3% distortion distort in
: Make and carry F.L. current of inverters at 0.8 p.f. : Make before break. :4 : Short time rating of the inverter for 1Sec & 150% of full load current for 2 minutes. : Manual. Page 49 of 97
4.12
RESISTORS AND RESISTANCE BOXES The resistors offered shall be arduous duty, industrial application, shock and vibration proof, unbreakable, rigid and rust proof punched chromium steel alloy grid and conforming to the requirements stipulated in IPSS 1-10-002-82 1 82 "Specification for resistance boxes for power circuits" with latest amendments. Cast iron resistors shall not be acceptable. The resistors shall be assembled on high quality asbestos or mica insulated high tensile steel tiee rods and separated from one another by mica or asbestos washers in required numbers and rigidly supported to eliminate vibration, breakage, displacement or deformation. Tappings shall be provided with every resistance element indicating resistance value to enable adjustments, if required. Individual grids shall be TIG welded at the junctions and terminal taps shall be welded to grids, ensuring a consistent current path. The grids shall be assembled on heavy steel frames which shall be suitably stacked, housed and mounted in minimum 2.5 mm CRCA sheet steel enclosed cubicles with louvers along with wire mesh to ensure good ventilation and mounted on a base frame of ISMC 125 . The panel of resistor units shall be free standing, floor mounting type and provided provided with two numbers of grounding pads, tapped holes and bolts suitable for connection of grounding conductor of 50x6 mm G.I flat. Enclosure shall be in single front execution. Individual banks shall be mounted on bracket welded to the frame, as such individual bank can be withdrawn out from enclosure without disturbing other banks. All resistor banks shall be provided with adequate lifting facility for handling during installation and over hauling. The terminals shall be brought out in the separate terminal box (IP-55) 55) on one side and marked with metallic tags for external connection with AYFY cables. The current carrying capacity of the resistor shall be so selected that the temperature shall not exceed 370 deg. C.
4.13
PLANT ILLUMINATION SYSTEM The scope includes complete plant illumination system to achieve required illumination levels as per IS or as per CBIP guidelines. The scope shall cover the following illumination systems: • • •
Normal AC lighting DC Emergency lighting. light Maintenance lighting Peripheral, road/street and area lighting within battery limit
Illumination shall be provided in all the following premises: 1. 2. 3.
Switchgear room at WT substation Battery room at WT substation Transformer rooms
Technical Specification:Sec-6, Electrical
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4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
A/C & ventilation Room R Peripheries of buildings Coal conveyor galleries Dust suppression MCC room Junction houses and transfer towers Wagon Tippler System Control room of WT MCC room for WT Roads/streets within battery limit Area/sub areas within battery limit Any other premise coming under the battery limit
The illumination system shall include the following in required quantities: Lighting DBs/ Sublighting DBs • Light fittings with lamps • Lighting fixtures and accessories • Cables and wiring • Ceiling fans • Receptacles • For street light LED lamps preferable High mast system should have Metal Halide Lamps
• • • • • • • •
Steel tubular poles Switches Conduits & brackets Hangers & clamps JBs Timers/photocell
All lighting in outdoor area such as cWT c areas, road/street and area lighting as well as peripheral lighting shall have auto ON/OFF facility with suitable 24 hrs timer. All the light fittings shall be dust and weather proof.
Illumination levels envisaged for different areas will be as indicated indicated below: S.N. Area 1 Switchgear room
Lux 250
Fitting type FTL
2.
Battery room
100
FTL
3. 4.
Transformer room MCC room
FTL FTL
5.
WT Control Room
200 250 lighting 250
6. 7. 8. 9.
Junction house Conveyor gallery Peripheral lighting Street / road / area lighting
200 100 20 20
MH MH MH SV
Technical Specification:Sec-6, Electrical
FTL
Remarks AC normal lighting DC emergency lighting AC normal lighting DC emergency lighting AC normal lighting AC normal lighting DC emergency AC normal lighting DC emergency lighting AC normal lighting AC normal lighting AC normal lighting AC normal lighting
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Lighting DBs of all the areas shall preferably be located inside the rooms like switchgear cum, control room, etc. Sufficient numbers of LDBs, SLDBs, lighting poles, 415/240 V switch socket outlets, ceiling fans with regulators, earthing pits, MCB controlled socket outlet, junction boxes, etc shall be considered under scope of the Bidder as per actual requirement. DC emergency lights shall be fed from separate DCELDB. Similarly, power receptacles shall be fed from dedicated Receptacles DB. DCELDB at WT SYSTEM substation shall be fed from Purchaser’s DCDB. Receptacle DB shall be fed from Bidder’s PDBs/aux. PDBs. icient numbers of DCELDBs and Receptacles DBs shall be considered by the Bidder as per Sufficient requirement. LIGHTING DISTRIBUTION BOARD (LDB) 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec.) indoor type. Board shall be single front, metal clad, clad, front matched, free standing, floor mounted, dust and vermin proof, non-draw-out, out, fully compartmentalized and extensible on both sides, IP54 type enclosure. Incomers shall be draw out type. LDBs shall have a series of panels of uniform height placed side de by side having front access for operation as well as cabling and access for maintenance of busbars. LDBs shall have two incomers and one bus coupler. Separate busbar compartments provided on the top shall have bolted covers in the front and rear. The main busbars shall have continuous current rating as required. The rating of the neutral busbar shall be 50 % of the phase busbars. The busbars shall be of aluminum alloy conforming to IS 5082. The busbar sizes shall be so selected that with the passage of rated current, the temperature rise over 500C ambient does not exceed 400C as measured by thermometer. Each cubicle shall have segregated feeder compartments arranged in tier formation with each compartment housing one feeder circuit with lockable hinged hinged door having neoprene gasket all around. Modular construction shall be adopted to cater for different sizes of feeders. The cubicles shall have common horizontal busbar chamber at the top and vertical risers at the back. The cable compartment shall be provided provided on the side with cable entry arrangement from bottom. The busbar and cable compartments shall be provided with bolted cover plates. The rear cover shall be easily removable type construction. The LDBs shall conform to IS 8623 for factory built assemblies, assemblies, IS 13947 for general requirement of switchgear and IS 5578 & IS 11353 – Guide for making and identification of conductors and apparatus terminals.
Technical Specification:Sec-6, Electrical
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The LDBs shall be fabricated from CRCA sheets with 2 mm thickness for all members except the doors of the modules, the rear covers, the covers of cable chambers and busbar chambers which may be of 1.6 mm with adequate stiffeners to prevent buckling. Non-load Non bearing partition walls may be of 1.6 mm thick sheet steel. The cubicles shall be made up of bolted sheet steel members and side panels of pressed sheet steel with neoprene gasket at all joints and openings including doors. Bus bars shall have same cross-section cross section throughout the length. Rating of the neutral bus bar ba shall be 50% of the main bus bar. Earth bus bar shall run in bottom chamber throughout the length of the panel. The LDBs shall have necessary provision at either end for future extension by bolting additional section. The busbar shall be supported with wi high quality non-hygroscopic, hygroscopic, insulating, self extinguishing and fire retardant insulating material, of adequate mechanical strength so as to withstand, without damage, effects of available short-circuit short circuit current. The busbars shall also be properly spaced d of facilitate taking vertical connections to individual units. The connections to individual units shall be taken by taped busbars. The busbars shall be of uniform cross-section cross and the main busbars shall run throughout the length of the board. Similarly vertical droppers shall extend for the full height of the panel except the bottom chamber. The connection between busbars of different metals as well as their connection with the terminals of the equipment shall be made in such a way to prevent corrosion and local heating. Liberal space shall be provided for cabling and to accommodate any conventional type of cable glands for PVC insulated and PVC sheathed armoured aluminum conductor cables. The cables compartment shall have provision for clamping of cables cables inside compartment on perforated sheet steel sections. The LDB shall have following meters in each of the two incoming feeders: • One no. digital type voltmeter with accuracy class of 1.0 • One no. digital type ammeter with accuracy class of 1.0 • One no. digital energy meters with accuracy class of 1.0 Suitable CTs with accuracy class of 1.0 shall be provided in the incomer modules for the above metering. Moulded Case Circuit Breakers LDBs shall have moulded case circuit breaker triple pole, air break type with independent manual quick make and quick break type. MCCB shall be capable of breaking rated current at 0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system and shall be current limiting type. All outgoing outgoing feeders shall have earth fault protection. Technical Specification:Sec-6, Electrical
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The MCCBs shall be suitable for panel mounting and shall be fixed type. All live parts shall be enclosed in moulded case and all contacts shall be silver plated. The breakers shall be trip-free trip and with quick make & break operating mechanism. The MCCBs shall sha be provided with ambient temperature compensated bi-metal bi metal overload releases and a magnetic short-circuit short release with inverse time characteristic. Releases shall be either static or microprocessor based. The operating handle shall be included with module module door such that the door can be opened only with the breaker in the “OFF” position. The MCCB handle after the breaker tripped due to a fault shall occupy an intermediate position. The breaker shall be capable of interrupting a full fault current corresponding onding to the fault level specified. MCCBs shall have a breaking capacity of 50kA at 415V. Current limiting MCCBs are not permitted. The LDB shall be consisting of following feeders: Incomer : Bus coupler : Outgoing : 63 A MCCB – 10 Nos.
2 Nos. each of 600 A MCCB with over current and earth protection. p 1 No. of 600 A MCCB 125 A MCCB
SUB LIGHTING DISTRIBUTION BOARD (SLDB) 415V, 3 phase, 4 wire, 125/63A (as applicable), indoor/outdoor type (as applicable) generally conforming to IS 13947 and IS 8623 as applicable. The SLDB shall comprise of one number of incoming TPN MCCB, three nos. of DP MCBs, and requisite number of outgoing SPN MCBs (as specified) and adequately rated bus bars. The SLDBs shall also have timer, contactors, A/M switch, etc as per requirement. The enclosure class of SLDB shall be IP 54. The terminals of MCCB shall be fully shrouded. The boards shall be of industrial, totally enclosed dust-proof, dust proof, wall mounted, sheet steel cubicle design. The thickness of the sheet steel shall be 2 mm. The boards shall have welded back and sides and gasketted hinged door at the front with door handle and suitable locking devices. For boards with incoming isolating switch the access to the operating handle shall be from the front of the cubicle without opening the front door. Operating knobs of outgoing MCBs shall be accessible only after opening the front door of the cubicle. Protective insulated cover plate shall be provided inside the cubicle to shroud all the live parts with only the operating operatin knobs of the MCBs protruding outside the cover plate. The boards shall also be dust-proof dust in door-open position. Adequate space shall be provided within the boards to facilitate termination of incoming and outgoing cables. The boards shall be factory wired wired and assembled. Where specifically called for, the boards shall be of special weather-proof weather proof design suitable for outdoor installation.
Technical Specification:Sec-6, Electrical
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The miniature circuit-breakers breakers (MCBs) shall be heat resistant plastic moulded type generally designed, manufactured and and tested as per IS 8828. Unless specified otherwise all MCBs shall be provided with quick break trip free mechanism and direct acting thermal overload and short-circuit circuit trip elements. The short-circuit short circuit breaking capacity of the MCBs shall not less than 9 kA at 0.8 power factor. Single-phase Single phase MCBs which are not provided with built-in built phase barriers, and mounted adjacent to each other and connected to different phases, shall be provided with adequate insulated phase barriers, shall be selected from standard current cur rating. The TPN busbars shall have continuous current rating as required. The busbars shall be of copper and sizes shall be so selected that with the passage of rated current, the temperature rise over 500C ambient does not exceed 400C as measured by thermometer. The minimum size of busbars shall be 25 x 3 mm. The busbars shall be properly supported with high quality non-hygroscopic, hygroscopic, self extinguishing and fire retardant insulating material of adequate mechanical strength so as to withstand, without damage, damage, effects of available short circuit current. The busbars shall also be properly spaced to facilities mounting of MCBs and taking connections to individual units. Detachable cover plate shall be provided at top and bottom for cable glands suitable for f PVC insulated, PVC sheathed armoured aluminum conductor cables or for direct entry of conduit. Cable terminals shall be suitable for aluminum conductor cables and so arranged to enable connecting of each circuit without disturbing any other circuits. Identification labels, inscription plates, danger boards, etc shall also be provided as per requirement. Earthing arrangement and danger plates shall be as specified. SLDBs shall have automatic group switching arrangement for which timer of robust construction uction and suitable contactors shall be provided in each board. Bypass arrangement of timer in form of auto/manual switch shall also be provided in the SLDBs. The controller shall sense the outdoor light and shall switch “ON” through auxiliaries contacts when w the sunlight falls bellow a present value. It shall remain in this position till dawn when it shall switch “OFF” when the sunlight remains a preset level. Suitably engraved identification labels and inscription plates shall be provided for each circuit. circu The same shall also be provided for the boards. One continuous G.I earth bus shall be provided in the bottom part of SLDB along the full length of the board with two bolted type earthing terminals to comply with the requirements of Indian Electricity Rules. Proper danger plates shall also be provided on each board. Each SLDB shall be provided with padlocking facility with sufficient number of keys. The following types of SLDBs shall be provided: SLDB, Type A (To be used for 2x40 W FTL light fittings) fittin Incomer
:
Technical Specification:Sec-6, Electrical
MCCB, 4 POLE, 63 A : 1 No. Page 55 of 97
Outgoing Outgoing
: :
MCB, DP (63 A) : 3 Nos. MCB, SPN (10 A) : 10 Nos./Phase (Total 30 Nos.)
SLDB, Type B (To be used for 250 W HPSV/MH light fittings inside the building) Incomer : MCCB, 4 POLE, 63 A : 1 No. Outgoing : MCB, DP (63 A) : 3 Nos. Outgoing : MCB, SPN (16 A) : 6 Nos. per phase (Total 18 Nos.) SLDB, Type C (To be used for 250W/150W/70 W HPSV/MH light fittings outside building) Incomer Outgoing Outgoing
: : :
MCCB, 4 POLE, 63 A : 1 No. No MCB, DP (63 A) : 3 Nos. MCB, SPN (20 A) : 5 Nos. per phase (Total 15 Nos.)
SLDB, Type D (To be used for 250 W HPSV/MH street light fittings) Incomer Outgoing
: :
MCCB, 4 POLE, 125 A : 1 No. MCB, TPN (63 A) : 8 Nos.
Sufficient number of SLDBs of different types (A, B, C and D) shall be used as per requirement of different areas and sub-areas sub areas of the coal handling plant. Exact quantity of SLDBs of various types shall be finalized during detailed engineering. Bidder shall shall consider as per requirement subject to minimum one number of each type of SLDB. RECEPTACLE DISTRIBUTION BOARD Receptacles DB shall be suitable for 415V, 3 phase, 4 wire, 125 A, indoor type. Board shall be single front, metal clad, front matched, dust dust and vermin proof, draw-out, draw fully compartmentalised and extensible on both sides, IP54 type enclosure. Shall have isolated busbar chamber for main busbar at the top, running through out the length of the board. Chamber shall have removable cover. usbars shall have same cross section through out the length . Rating of the neutral busbar Busbars shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the length of the panel. Shall have Moulded case circuit breaker (MCCB) triple triple pole, air break type with independent manual quick make and quick break type. MCCB shall be capable of breaking rated current at 0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system. Generally all boards will have following f feeder arrangement. Incomer
:
Technical Specification:Sec-6, Electrical
MCCB TPN of 125A : 1 Nos. Page 56 of 97
Outgoings
:
MCCB TPN of 32 A : 10 Nos.
220V DC Emergency LDB (DCELDB) The DCELDB used for emergency lighting distribution shall be industrial heavy duty type suitable for 2-wire 220V DC operation, and shall have a DC double pole power contractor and requisite number of auxiliary contractors and timers and outgoing feeders protected with DP MCBs of suitable ratings. The incomer shall be of double pole load break design suitable for for operating on 220V DC. The enclosure shall be made of 2 mm thick sheet steel and shall have requisite number of cable glands and terminal strips for incoming and outgoing cables. The control circuit voltage shall be of 220V DC. The DCELDBs which feed all all the emergency lighting points shall be automatically switched on the event of power failure through a separate circuit which sense under voltage of normal AC supply at the specified location. These emergency lighting fittings shall glow for a preset time tim and shall be switched OFF automatically through a time relay in case the normal AC power supply is not restored within that time. Feeder configuration of DCELDB shall be as follows: MCCB, DP (63 A) – 1 No. Incomer : Outgoing : MCB, DP (10 A) – 16 Nos. Supply of battery, battery charger(FC & FCBC, DCDB for 220V DC system shall be in bidder’s scope. 415 V switch outlets Switch socket outlets and plugs for 415 V, 3-phase 3 phase circuits shall be of four-pin four (three pole and one earth), non-reversible reversible type typ enclosed in dust-proof proof 2 mm thick sheet steel enclosures. The socket outlets shall be provided with fuses and shall have isolating switch interlocking as per IS:4160 such that it can be switched ‘ON’ only when the plug has been inserted and plug can be provided rovided for the socket outlets. The isolating switches shall be of category AC 23 conforming to IS 13947 (Part 3). The socket outlet shall be suitable for terminating aluminum conductor cables either directly or through GI pipe and shall be provided with compression c type lugs. The socket outlet shall be supplied with metal clad plug. The socket outlets and plugs shall have porcelain base and shall be of 32A rating. proof enclosure shall be used for outdoor installation. Inscription plate shall be Weather-proof provided indicating the voltage rating for the switch outlet. 240 V switch socket outlets Socket outlet for 240 V supply shall be of 3-pin 3 (two-pole pole and one earth) nonreversible, metalmetal clad, dust-proof, proof, industrial type suitable for horizontal insertion generally as per IS 1293. 240 V Technical Specification:Sec-6, Electrical
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socket outlets shall be controlled by rotary type switch mounted flush in the socket outlet box. Operating handle of the rotary switch shall be fixed in such a manner that it will not be possible either to insert or to withdraw withdraw the plug without switching off the supply. All socket outlets shall be supplied with heavy duty type plug and cap with chain. The isolating switches shall be of industrial type of category AC 23. The isolator shall be housed in dust and verminvermin proof sheet heet steel enclosure suitable for terminating aluminum conductor cables either directly by means of cable gland or through conduits. The current rating for the socket outlets shall be 20 A. Wherever called for HRC fuses shall be incorporated in the socket outlet box. Inscription plate shall be provided indicating the voltage rating and feeder identifications for the switch socket outlet. MCB Controlled Socket Outlet The MCB controlled socket outlet shall be similar to the above switch socket outlet and provided with industrial type socket outlet with cover suitable for 240V, 20A single phase AC and controlled through single pole 20A MCB. Ceiling Fans and Regulators Ceiling fans regulators shall be designed, manufactured and tested as per IS:374. The fans shall have totally enclosed, capacitor start and run motors, suitable for operation on 240V, single phase, 50 Hz AC system. The electronic type regulator shall have ‘ON’ – ‘OFF’ position next to the lowest speed contact, shall be provided with necessary harmonic filters and shall be suitable for operation at 500C ambient temperature. Down rods required for installation of ceiling fans shall be included by the Bidder. Bidde Lighting Poles Steel tubular road lighting poles with single outreach shall be of swaged and welded construction conforming to IS:2713-1969 IS:2713 with latest amendments. The outer surface of pole above foundation shall be painted with two coats of red oxide o zinc chromate primer paint as per IS:2713 and finished with two coats of synthetic enamel paint of approved shall not be less than 100 microns. The outer surface of the pole embedded in concrete foundation as well as the entire inner surface shall bee painted with two coats tar based general type black paint. The poles shall be provided complete with fixing arrangement for loop-in loop in and loop out box and lighting fittings. The Bidder shall submit a drawing indicating the general arrangement and the finall design and arrangement shall be subject to purchaser’s approval. The 415 loop-in loop-out out box shall be weather-proof, weather proof, dust tight, sheet steel enclosure suitable for outdoor installation. The box shall have hinged front with front locking device. 3 Nos. open Technical Specification:Sec-6, Electrical
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type terminals for taking looping connection of 4C x 16 sq.mm Al conductors. Conductor power cables and 2C x 2.5 sq.mm PVC copper wiring cable through rewirable fuse cutout to the control gear. The box shall be supplied complete with 63A terminal block, blo 5A rewirable fuses cutouts, brass / aluminum alloy cable gland, clamps, lugs, earthing terminals, danger plates and other required hardwares. Street lighting pole shall have a single outreach suitable to hold the street lighting fitting. Flood lighting ng pole shall have a cross bar on top of the pole and shall be suitable for fixing the flood light fitting. Earthing provision of lighting poles 2 Nos. 8 SWG GI wire shall run throughout along with street light poles in loop in loop out arrangement. One number of earth pit shall be provided for every 5 nos. of lighting poles. Each earth pit shall be consisting of 40 NB GI pipe of 3 mtr length, funnel, funnel, salt, charcoal, cast iron cover, clamps, etc. Junction Box The 415/240V, TPN junction boxes shall be of fabricated from 2mm thick sheet steel suitable for mounting on wall / column. The box shall have suitable provision for entry and termination of aluminum conductor, PVC insulated cable supplied complete with terminal blocks, earthing terminal, wire support etc. The box shall be painted with anti-corrosive anti corrosive primer both inside and outside and furnish with two coats of approved colour paint. The junction junct boxes used outdoors shall be with suitable canopy arrangement. The junction boxes shall be suitable for terminating one (1) incoming cable and two outgoing cables. Lighting Fittings High Mast light fittings shall be with Metal Halide (MH) lamps).All lamps).Al other fittings shall be with LED lamps. All lighting fittings and accessories shall be manufactured from best quality materials and shall be completed in all respect ready for installation at site. Unless otherwise stated lighting fittings shall have provision for 25 mm / 19 mm dia conduit (as applicable) entry for low-bay low bay fittings. Medium bay fittings shall have eyebolt suspension arrangement. Terminals off all fittings shall be suitable for connecting 2.5 sq mm flexible, copper conductor, PVC insulated ted and PVC sheathed cable for low-bay low bay fittings and 2.5 sq mm flexible copper conductor cable for high bay fittings. All the LED fittings and MH fittings shall be non-integral non integral type. Control gear boxes shall be mounted at man height for ease of maintenance. maintenanc
Technical Specification:Sec-6, Electrical
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High mast fittings (Non-integral integral type) : 2 nos integral type asymmetrical beam flood light fittings with 2x400W MH lamps complete Non-integral with control gear, accessories, etc suitable for installation on 30 M high lighting mast as per technical specification ion (Bajaj BGENF 22 or equivalent with MH lamps) shall be mounted on the lantern carriage of each of the high lighting mast. Lamps All lamps shall be of high lumen output and with long life. Incandescent Lamp All general service incandescent lamps shall be gas filled, clear finished and coiled coil type where possible. Incandescent lamp cap shall be of screwed type having GES/ES thread depending on the sizes of the lamp. Fluorescent Lamp mps shall be of day-light day light type unless otherwise specified and shall be suitable All fluorescent lamps for suitable for switch-start start with bi-pin bi type cap. Sodium vapour lamps shall be suitable for universal burning position. The elliptical outer bulb shall be coated inside the diffusing powder and shall have good colour appearance. The sodium vapour lamp shall be of screwed type E40/E27 base depending upon the wattage of the lamp. Ballast The ballast shall be of electronic type and well tried out design to give trouble-free trouble operations with long service life having provisions for suitable tappings in steps. Capacitor Capacitor shall consist of element wound from layers of higher purity aluminum foil and capacitor paper contained in aluminum cylindrical can. The capacitor shall sh be vacuum dried and impregnated. The can shall be hermetically sealed and terminals provided over porcelain insulations. The capacitor shall conform to IS 1569. Lamp Holder The lamp holders shall have spring loaded contacts for positive contact with wit pins so as to prevent the lamp from being extinguished due to vibration. The holder shall be such that the lamps can be removed easily whenever required for cleaning or replacement purposes. For fluorescent lamp, bi-pin pin lamp holder shall be provided. The The holder of incandescent lamps upto 200 W shall be of ES type. Technical Specification:Sec-6, Electrical
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The starter holders shall be of well tried-out tried out design and of robust construction with provisions for easy insertion and removal of the starter ensuring correct contacts by means of strong spring action. Push button for group switching of lights h buttons (one no. ON and one no. OFF) shall be mounted on cast iron box with The push 2NO+2NC contacts and terminal block. Conduits and Conduit Fittings Surface conduit installation shall be carried out using hot dip / electro galvanised rigid steel seamed by welding, screwed type, designed, manufactured and tested in accordance with IS 9537. The various conduit accessories like couplers, bends, elbows, reducers, saddles, clamps, lock nuts, junction boxes etc. shall conform to IS 3837 shall be supplied and erected erec as per requirement along with the conduits. Point wiring materials and Accessories The point wiring materials and accessories for lighting for installation, fan points, sockets etc. where specified shall include wiring cables, conduits and conduit fittings, wiring accessories inclusive of switches, sockets, fan regulators, switch boxes, junction boxes etc. Point wiring The wiring cables used in point wiring installation shall be 1100 volts grade PVC insulated single core flexible stranded copper conductor type confirming to IS:694. The size of conductors to be adopted shall be 2.5 sq.mm for lighting, fan and 5/15A socket outlet circuit and 2.5 sq.mm for 15A socket power circuits. Wiring Accessories The various electrical wiring accessories viz. viz. Switch boxes, switches and sockets shall confrom to IS 5133, IS 3854 and IS respectively. The switch boxes shall preferably be of passed sheet steel cadmium coated and passivated or galvanised with knockouts at the top and the bottom for conduit entry. The surface mounted type boxes shall have necessary provisions for mounting on the wall. Earthing terminals shall be provided in the box. Junction boxes provided at intermediate points shall also be identical in construction to the switch boxes. The switch and junction boxes shall be of standard dimensions with adequate wiring space. The switches and sockets shall be made of superior quality engineering plastic with excellent dielectric properties. The switches shall be of piano key design and shall have adequately adequately rated switch contacts. The switch contacts shall be silver tipped electrolytic grade copper. The switch plate forming part of the switch box cover shall be made of plastic material and shall be made with
Technical Specification:Sec-6, Electrical
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number of slots in which the switches and sockets sockets shall be assembled. The sockets shall be of three pin design with phase neutral and earth conducts. Earthing All electrical equipment shall be effectively earthed as to meet the requirements to Indian Electricity Rules and IS:3043. IS:3043. Earthing conductors for individual equipment shall be of either galvanised mild steel flat or stranded/solid G.I. wire as specified. Earth pits for street/area lighting poles The earth pits shall be consisting of 40 NB GI pipe of 3 mtr length, funnel, funnel salt, charcoal, cast iron cover, clamps, etc. The Bidder shall include all civil work as per requirement. All accessories shall be included as per requirement. 4.14
LIGHTING HIGH MAST WITH FLOOD LIGHT FITTINGS General lighting shall be factory fabricated mild steel plates welded, a. High mast tower for floor lighting polygon section, hot dip galvanized and provided in standard lengths. b. The structure shall be 30 meter high, well tried, proven design to withstand high wind speed of 180KM/ hr. ave a movable lantern carriage tower from the top of tower to bottom and c. The mast shall have vice-verse verse with the help of a motorised winch arrangement (with motor of minimum 2.2 kW capacity) and shall be provided with suitable gears, pulleys and ropes. The reeling of ropes shall all be such that to prevent twisting & tangling. Means shall be provided for normal operation of the winch in case of failure/ non availability of power to the motors. Safety of lantern carriage in case of breakage of the rope shall be ensured by arresting free fall of the lantern carriage to the ground by providing Safety locking arrangements. d. All the carriage components shall be galvanised and mounted inside the tower. The tower shall be provided with a suitable man entry door at the bottom section to facilitate inspection and maintenance. The door shall be weather proof and provided with safety safet lock to prevent unauthorised access. e. The lantern carriage shall be symmetrical, robust construction housing the luminaire and control gear boxes. The cables to the luminaries shall be run inside the tubes of the lantern with junction boxes provided for branch off cables. f. Proper luminaries carriage ring support arms shall be provided for supporting the luminaries’ carriage ring when the latter is lowered for maintenance of luminaries. Lantern carriage ring should be in channel tube and with concealed wiring wiring the carriage should be
Technical Specification:Sec-6, Electrical
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essentially have a 3 points suspensions system. The mobile luminaries carriage shall be evenly balanced Rubber Paddle Guide Ring shall be incorporated as a buffer arrangement between mobile luminaries carriage and mast shaft. This This is to prevent damage to mast surface during raising and lowering operation of mobile luminaries carriage. g. The winch shall be provided with a separate control panel housing the control for the winch drive motor and controls for switching the luminaries. luminaries. It shall be complete with switch fuse units/MCCBs, starters, contactors, etc that may be necessary to the operation of the light tower. It shall be suitable for outdoor installation with IP-65 IP 65 degree of protection. It shall be suitable for mounting on a suitable plinth adjacent to the high mast tower. self sustaining type without the need h. The winch must be of robust design and completely self-sustaining for brake -shoe, shoe, springs or clutches. It can be removed from the mast for maintenance if the need arises in the future future with the lower carriage on the top. The reduction gear of the winch shall be of endless worm gear, operating in oil bath. The minimum safe working limit of the winch shall not be less than 750 Kg. when the mobile luminaries ring is i. A minimum 6 turns of wire rope shall be on the drum when fully lowered to rest on the luminaries supporting arms. j. The winch is entirely selfself sustaining under all normal circumstances and it is not dependent on the brake or restraining device that uncontrolled or dangerous runaway runaw speed shall occur in the event of the total failure of this device. Slip test on winch is carried out by the manufacturer. Test certificate and report shall be submitted up, on request. shall be at least 1.5 meter Per k. The speed of the raising and lowering of lantern carriage ring shall minute. l. The high mast shall be fitted with flexible standard G.I / S.S. hoisting wire ropes of 7 x 19 construction with a minimum breaking strength of 1900 kgs. The combine lifting capacity of the hoisting wire ropes shall have have a factor of safety not less than 5 times the safe working load (SWL) of the winch and shall be entirely suitable for the design application. m. A transition plate shall be incorporated to balance the carriage from below of the mast. n. Cable for lighting and winch control shall be as per approved scheme. The cables shall be clamped or rolled so that no twisting of cables happens while the winch is hoisted or lowered. Electrical cable shall be PVC coated round flexible cable suitable for small bending radius. One standard multi core flexible electrical cable with 4 sq mm conducting areas shall be provided for connecting of power supply to the light source and shall terminate at the stationary connecting board in the base compartments. o. The high mast shall be suitable for asymmetrical loading of with 16 nos. of 2 x 400 W MH luminaries mounted on the lantern carriage. The luminaries shall be grouped in individual 240V RYB circuits fed through time switches. It shall be possible to switch the t lamp bypassing the timer. The timer shall be programmable digital/analogue quartz controlled, Technical Specification:Sec-6, Electrical
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high accuracy real time clock. It shall be set from 6 PM to 6 AM or any other intermediate time. The tendered shall indicate the controls offered by him clearly clearly in the offer. p. The successful Bidder shall submit design and preliminary data for the design of foundation of the high mast tower indicating the requirements of embedded inserts etc. The foundation shall be designed and provided by the purchaser. Bidder to include foundation bolts etc which shall be embedded in the foundation. Grouting of the bolts shall be done by the Bidder. q. The high mast shall be provided with lightning protection with airair termination and downdown comers as per requirements of BIS and aviation warning lamps as per statutory and civil aviation requirements. All metallic portions of the high mast shall be effectively earthed and provided with two earth pits near the base. Effective earthing for luminaries shall be provided during normal operation o and in lowered position. (Part r. Mast structure is designed to withstand wind velocity conforming to IS 875 (Part-III)-1987. Mast Design Criteria The high mast and the lowering system with the required number of floodlights and lamp controls gears etc. tc. In place shall be capable of withstanding a sustained basic wind speed of 180 Km/ hrs. The design shall be in such a manner that it is capable of withstanding external forces exerted by wind pressure and should have a minimum wind load factor of 1.25 and material factor of 1.15. Design life of mast shall be 25 years. CONSTRUCTIONAL FEATURES OF MAST The mast shaft shall be made with the best steel grade, in compliance with MS ISIS 2062/BSEN 10025 having adequate characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for thickness. The steel grade for accessories shall also be MS IS 2062 or equivalent, having adequate characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for thickness. Each mast section to be delivered to site shall have a minimum length of 10.7 Mtrs. The Mast sections shall have Single longitudinal weld from Bottom to Top. The base shall have a flange plate for high mast onto the concrete foundation by anchor bolts. The mast shall be fabricated and welded longitudinally to form a tapered section with telescopic friction on slip joints. All welding shall be to IS 816 / 82 having the following basic requirements.
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The wall thickness of each section shall be designed to withstand the loads to which the high mast shall be subjected to, but shall not be less than 8 mm for base section and 6 mm for other sections and minimum base dia shall not be less than 530 mm. Connection between the various sections, shall be achieved by telescopic slip joints, the overlapping length being at least 1600mm slip joint assembly shall be perform at site. Shaft section shall not be joined by circumferential weld or bolting at site. The base plate shall be free from lamination lamination and shall be single flange constructed with holes jig drilled for anchor bolts passage. The bottom of the base mast section shall be securely welded to the base plate by complete penetration fillet welding. The welded connection of the base plate to the mast section shall fully develop the strength of the section. The base section shall be equipped with a hinged service door. The service door opening shall be complete with a close fitting weatherproof and equipped with a vandal resistant lock. The service ervice door shall not be smaller than 1400 mm x 300 mm the opening shall be reinforced by a thick steel door frame. Base plate of suitable dimensions and thickness, diameter, size and the placement of anchor bolts shall be determined by calculations. Anchor Anchor bolts shall be of deformed steel reinforcement bars having the adequate characteristics w.r.t. tensile strength. Welding of two or more anchor rods of shorter lengths to achieve the design length shall not be permitted. No welding shall be allowed on o the anchor rod body. Adequate earthing and earthing terminal shall be provided within the access door area of each Mast. All high mast shall be hot dip galvanized, in accordance with IS 2629 / TR 7 Timer control panel shall be provided with overload and single phase preventor. Timer control panel shall be outdoor type. Motor capacity of the winch Motor shall be of hoist duty and of adequate capacity with 15 % minimum margin over mechanical power requirement. Minimum capacity of 2.2 kW shall be considered. consi 4.15 EARTHING AND LIGHTNING PROTECTION EARTHING PROTECTION Bidder shall include complete earthing of WT substation, MCC rooms, Wagon tippler, apron feeder & conveyor drives etc. The underground earthing mats also shall be done by the Bidder. Risers shall be available at all the premises for interconnection of own earthing network. However, Bidder shall provide provide complete separate earthing for transformer neutrals. Bidder shall include the following in each and every substation: Technical Specification:Sec-6, Electrical
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1. 2. 3.
Earthing ring mains at WT substation and all the electrical rooms/premises Equipment earthing Transformer neutral earthing providing prov dedicated pits
Bidder shall include complete earthing material including earthing strips, earth electrodes other accessories for treated earth pits, etc. and carry out earthing ring mains, earth pits, interconnections, equipment earthing, all associated associated civil works, etc at all the ubstations. All the connections of earthing ring mains with available underground earthing grid of respective substation/premise shall be under scope of the Bidder. Separate dedicated treated earth pits shall be provided provided for transformer neutrals. Two nos. such earth pits shall be provided for each of the transformers. The treated earth pits shall be consisting of 3 mtr 65 NB GI pipes, funnels, clamps, 3 mtr long 40 mm MS rod electrodes, MS cover with lifting lugs, associated assoc civil works, etc. All the equipment located in the WT premises / sub-premises sub e.g. 33 KV switchboard, LT PCCs, busducts, transformer bodies, charger panels, DCDBs, LDBs, SLDBs, receptacles, control panels, MCCs, etc shall be connected by the Bidder with earthing ring mains at least two different points. Electronic earthing shall be considerd for PLC, etc Bidder shall also consider earthing of following equipment to be installed by the bidder. • 33kV kV WT switchboard at WT substation in switchgear cum MCC room • WT distribution transformers (2 nos.) – Neutral as well as body earthing • 415 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room • Control panel for power distribution equipment at existing WT control room • LT busducts (2 sets) • Charger panels, DCDB, etc at WT substation in switchgear cum MCC room Bidder shall consider earthing ring mains at each electrical premise and connect the electrical equipment with the rings. The earthing ring ring mains shall be connected with underground earthing mats (consisting of 2x40MM dia to be installed by the bidder.. For transformer neutral earthing, bidder shall consider dedicated plate earthing. Bidder shall include complete earthing material including including earth electrodes, risers, GI earthing strips, other accessories, etc. and carry out main earth grid mat, earthing ring mains, earth pits, risers, interconnections, equipment earthing, all associated civil works, etc within battery limit of the package. Allll the interconnections with other earthing systems of the plant and with existing systems shall be under scope of the Bidder. The Bidder shall obtain the actual soil resistivity of the plant area by carrying out soil resistivity tests and design the earthing thing system accordingly.
Technical Specification:Sec-6, Electrical
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While designing the earthing system, Bidder shall note the following fault levels at 415 V bus shall be 50 kA. Plant earthing system shall be designed such that overall earthing resistance is less than 1(One) Ohm without interconnections. interco The materials shall be galvanized steel laid over the ground and mild steel buried inside the ground/concrete. Fault clearing time for sizing of earth conductors and for calculations of the maximum allowable step and touch potential shall be taken 1 sec. Maximum allowable temperature rise for steel bolted joints shall be taken as 3100C taking ambient temperature of 50oC. The earthing system shall be generally designed on the basis of the following codes & standards: • IS 3043 Code of practices for safety and standards • IEEE 80 Guide for safety in AC substation grounding • Indian Electricity Rules Entire system shall be earthed so that the values of the step and contact potentials in case of faults are kept within safe permissible limits. limit Parts of all electrical equipment and machinery not intended to be alive shall have two separate and distinct earth connections each to conform to the stipulation of the Indian Electricity Rules. In case of HT system, E/F current will be made to flow through copper screen tape provided over inner sheathing. Screen will be connected to earth bus at both ends. In case of LT the TNTN S system will be followed, i.e. neutral bus of the switchgear shall be connected to switchgear earth bus and then to DBs shall sha be through armouring of cable. Bidder shall submit the layout drawings of earthing network with supported calculations for approval of purchares/consultant. Taking approval of Electrical inspector/CEA and providing all inputs to them like data/drawings data/drawing are under scope of the Bidder. The materials shall be galvanized steel laid over the ground and mild steel buried inside the ground/concrete. Earthing of SLDBs, power receptacles, etc shall be connected with respective source LDBs through armouring off cables. Earthing conductors run on walls/floors/cable and equipment structures etc. shall be supported at suitable intervals and painted with black oxide paint. The armour of cables and all conduits for cables shall also be connected to the earthing mains. m A continuous earth strip shall run in each side of cable channel and in cable ducts/tray route. All joints in the branch connections except at earthing electrode shall be welded and painted black. At road/rail crossings earthing strips/rods shall be laid through conduits/concrete ducts. Technical Specification:Sec-6, Electrical
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The armour of cables and all conduits for cables shall also be connected to the earthing mains. A continuous earth strip shall run in each side of cable trenches. All joints in the run of the main earthing conductors will be welded or brazed type. Connection to equipment structure shall be bolted type. All welded joints joints shall be protected from corrosion by applying bitumen paint. Earthing system shall be distinct and separate from the lightning equipment earthing system. Earthing Conductors and Installation Accessories for Equipment Earthing System All electrical equipment installed by the successful Bidder as well as equipment installed by Purchaser shall be effectively earthed in conformity with relevant clauses of Indian Electricity Rules (1956) and in accordance with IS: 3043 to the complete satisfaction satisfaction of the Chief Electrical Inspector to Government of Orissa State. All non-current non current carrying metallic conduit parts of various electrical equipment as well as cable armouring, metallic conduits, GI pipe, cable racks, trays, brackets, supporting structures structures etc. shall be effectively earthed. Main earth mat comprising 40 mm dia MS rods and earth electrodes and riser upto + 1.0 M level shall be supplied and installed by the ownr. All other equipment to complete the earthing of equipment installed by the Bidder shall be in the scope of the Bidder. The Bidder shall also connect his sub earth mat to the main earth mat provided by the Bidder. Conductor size adopted for earthing ring shall in no case be less than that of the earth continuity conductors connected connected to it. The size of conductors used for overground sub earth mat in switchgear rooms/ control rooms/ plant buildings/ areas shall be 65 mm x 8 mm galvanized mild steel strips. 50 mmx 6mm galvanized MS strips will be used for earth buses inside the buildings/ ldings/ floors/ platforms etc. and also for earth conductors laid along cable trays. For buildings having a number of floors, separate earthing ring shall be established in each floor and shall in turn be connected to the Purchaser’s earth mat. Separate earthing system shall in no case have cross-sectional cross sectional area less than 6 sq mm stranded GI wire. Size of earth conductors selected for system earthing and earthing of various equipments shall be as follows. Galvanized Iron flat conductor strips shall be used for neutral earthing. The minimum size of conductors for neutral earthing of various transformers shall be as given below unless a higher size is required from the viewpoint of higher available fault current. tran : 75mm x 10mm LV neutral of 33/0.440 kV, 1600 KVA transformers The minimum size of galvanized Iron flats for earthing of various equipment shall be as follows: Technical Specification:Sec-6, Electrical
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Ring mains LT PCCs/board Control Panels LT Busducts DC Distribution Board LDB SLDB Push button station Transformer bodies Cable tray (running earthing)
: : : : : : : : : :
75mm x 10mm 65mm x 8mm 50mm x 6mm 50mm x 6mm 50mm x 6mm 50mm x 6mm 25mm x 3mm 6 sq mm stranded 50mm x 6mm 50mm x 6mm
LIGHTNING PROTECTION d plant structures including switchgear building and junction houses shall be All buildings and protected against atmospheric flash over and lightning strokes in such a manner as to eliminate any danger to the personnel employed therein. Stipulations of IS : 2309 - 1969 shall be followed. A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel structures crossing this cage ring shall be laid around plant as earthing device. This shall be separate from the electrical equipment earthing ring ri main. Design shall be as per the standard like IS 2309 (latest revision) and Indian Electricity Rules. All lightning arrestor earth leads of the plant shall be connected to this cage ring. Air termination network should cover all salient points of the structure. All metallic structures, ducts and the like above the roof of the structure shall be bonded to and form part of the air termination network. Vertical air termination points shall project at least 30 cm above the object on which it is fixed. Down conductors shall follow the most direct path possible between air termination and earth termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the earth electrode. Each conductor shall have an independent earth termination. All earth terminations shall be interconnected. Earthing electrodes and grid for lightning protection will be distinct separate from the earthing system for earthing of electrical equipment and at no place will be connected to other earthing system. 4.16
MISCELLANEOUS ELECTRICS SAFETY
Technical Specification:Sec-6, Electrical
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All equipment shall be complete with approved safety devices wherever potential hazard to personnel exists and with provision for safe access of personnel to and around equipment for operational and maintenance functions. The design shall include all reasonable reaso precautions and provisions for the safety of operating and maintenance personnel. Special care shall be taken to make enclosed equipment proof against entry of rats, lizards and other creeping reptiles which may create electrical shortshort circuits inside side live equipment. MINOR CIVIL WORKS Minor civil works associated with cabling, earthing, conduit installation, illumination systems, lighting poles, for buried cables, for erection of equipment supplied by the Bidder, foundation of lighting masts/poles, es, etc shall be included under scope of bidder. Similarly minor civil works like widening of floor openings / cable trenches, wall opening for cables, minor chipping, etc shall be included under scope of bidder. LOCAL CONTROL STATION Near all drives local cal control stations shall be provided. Local stations shall have Cast Aluminium body, dust and vermin proof, and structure mounting. Stat and stop push buttons shall be mounted on front hinged gasketted and lockable door. Local/remote selector switches shall all be provided on local control stations. Stop push button shall be lockable type. In addition, ammeters shall be provided on local control stations for HT drives. Suitable knockouts with glands shall be provided on the bottom or top cover for cable entry. entry. Terminals shall be suitable for 2 cores of 2.5 sq.mm conductors with 10% spare terminals. Enclosure shall be conforming to IP55 with proper rain canopy. ELECTRICS OF DUST SUPPRESSION SYSTEM Bidder shall include complete electrics of dust suppression systems coming in the scope within the battery limit. Bidder shall provide complete electrics including MCC, drives/mechanism, associated cabling & their termination, local DBs, all power and control ccessories, all related annunciations, etc. ELECTRICS OF AIR-CONDITIONING CONDITIONING AND VENTILATION SYSTEM Bidder shall include complete electrics of air-conditioning air conditioning system and ventilation system. Complete electrics for the following shall be included: • Ventilation system for the switchgear cum MCC room at WT SYSTEM substation • Exhaust fans for the two numbers transformer rooms at WT SYSTEM substation • Air-conditioning conditioning system for the battery and battery charger room at WT SYSTEM substation stem for dust suppression MCC room • Ventilation system
WT SYSTEM ELECTRICS OF HOISTING AND HANDLING EQUIPMENT Technical Specification:Sec-6, Electrical
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Bidder shall include complete electrics of hoists coming in the scope within the battery limit. Bidder shall provide complete electrics including source feeders, associated cabling & their termination, local DBs, all power and control accessories, all related related annunciations, etc. All the hoist control panel shall be located at workable height and platform shall be provided for each hoist at one point for maintenance purpose. 33 KV OVERHEAD LINES In coming power supply to Wagon tippler, apron feeder, & conveyor system will be taken from 33KV Lean Slurry substation located near the 220KV switch yard with provision of lighting arrester, load brake switch, 33KV VCB, CT,PT relay and control panel housed in a suitable building comes under bidder’s scope. Laying Laying Power cable/Transmission line from the substation to wagon tippler area along with provision of transformer, switch gear system & panels will be the scope of the bidder. Approximate distance from the substation to the wagon tippler area will be 2.00 Km. Km. However, actual distance & Suitable route for laying of cable will be assessed by the party in consultation with NALCO. The transmission line(33 KV) where ever crossing roads shall be through double run underground cabling arrangement as per relevant regulations. gulations. The bidder shall also execute underground cabling and other necessary work for crossing railway track of the existing Intake Pump House and Ash pond 33KV overhead transmission lines with provision of DP,lighting arrester and associated switchgear. switchge Cost of power cable/transmission line shall be in scope of bidder. RS joist poles of size to 200 X 100 mm shall be erected by excavation of pit size 700 mm X 700 mm to a depth of 1/5th of the pole. The pole shall be erected upright to the plumb. MS channel shall, be used for ‘V’ type cross arm of size 100 X 50 X 6.4 mm. The spacing between two extreme conductors shall be 1100 mm and the 3rd conductor shall be provided on the top of the mast. Suitable porcelain pin type insulators shall be used. A continuous con earth wire shall be provided for RS joist pole earthing and securely fastened to each pole and connected to earth, at 4 points in every 1.6 km, the spacing between the points, being as nearly equidistant as possible. Galvanized steel guard wire mesh mesh having breaking strength of 635 kg shall be connected to earth at different points and shall be used in over head while crossing street/passage. Suitable lightening arrester shall be provided in the four pole structure.
V overhead transmission line will be decided by the bidder in Suitable route for 33KV consultation/coordinating with NALCO to avoid any local/field interference. HT transformer of suitable capacity (33KV/0.44KV) KV) will be supplied by the bidder confirming to latest features. Supplyy of associated switch gear and measuring equipments will be supplied by the bidder for the HT system.
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Technical details of HT transformer and other switch gear will be submitted to NALCO / RITES for its approval. The conductor for 33KV line shall be of ACSR ACSR (dog/Rabbit) type. The HT transformer (33KV/0.44KV) (33KV/ shallll be located in the near the wagon tippler area. The switch gear will be designed in conformity to CEA norms having provision of LA, PT, CT, ISO etc. Fencing and development of switch gear will be the scope of the bidder. The switch gear will be located near wagon tippler area. Room size to be decided by the bidder to house all required equipments (HT & LT switch gears) at the ground floor. WT Control room and operating panel will be located at at first floor of the building. Bidders are also advised to visit the site and assess the actual quantum of work to be done for this diversion and include accordingly. The operation of the WT SYSTEM plant shall be monitored and controlled from the proposed WT control rooms by means of VDU operator interface on a microprocessor based programmable logic controller (PLC). The system shall be envisaged for the purpose of initial operation, protection and interlock, data acquisition, close loop control, data archiving, a etc for fully automatic operation. The system shall be capable of monitoring and displaying the status of equipment, including the analog and digital signal displaying of status in the form of diagram, trend bar chart, overview, logs, etc with the the help of CRT, keyboard, mouse and printers. Necessary hardware and software license of the proposed PLC shall be provided. provided PLC programme, ladder logic and control philosophy shall be submitted by the bidder for approval of NALCO/RITES. The preferred make of PLC shall be GE-FANUC GE make.
33 kV Unit Vacuum Circuit Breaker 33 kV indoor Vacuum Circuit Breaker shall conform to the following technical particulars:
i) ii) iii) iv) v) vi) vii)
Type Quantity System Voltage Maximum system voltage Continuous current Rated short time current rating Interrupting capacity at 36 kV
Technical Specification:Sec-6, Electrical
Indoor, Vacuum type, electrically operated, trip free type, panel mounted 33 kV 36 kV As per requirement 31.5 kA for 3 sec 31.5kA
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The VCB shall be indoor drawout type with numerical type over current (50+51), earth fault (51N) relay with timer for instantaneous overcurrent protection as we as master trip and trip circuit supervision relay. The VCB shall be capable of withstanding through fault current of 31.5kA for 3 sec. and shall be provided with remote closing and tripping facilities. Under voltage relay with timer shall be provided in line PT. transformer nsformer differential protection shall also be provided. PT shall be provided with protection core of 3P class and metering core of CL 0.5. CT shall be provided with protection core of 5P20 class and metering core of CL 0.5. For transformer transformer differential protection PS class CT shall be considered. The closing coil of the breaker shall be suitable for operation between 85 to 110 percent of 220 V DC control power supply voltage available from batteries. The circuit breaker shall have redundant shunt trip device. The trip coil shall be designed to operate satisfactorily when the voltage at the terminals of the shunt trip coils is between 70 to 110 per cent of 220 V DC control power supply voltage available from batteries. VCB B shall be provided with dual trip coil. For actuation of trip coils, similar set of contacts shall be provided separately for each trip coil. Hence, necessary arrangement for duplication of contacts shall be done inside the panel panel if multiple No. of similar contacts are not available. The circuit breaker shall be power operated with motor wound spring closing mechanism with electrical spring release coil. The motor shall be suitable for operation on 240 V AC single phase supply. Means shall however be provided for manual operation of the breaker under emergency or for testing and adjustments. The operating mechanism shall be anti pumping and trip free type. perated mechanism shall be so designed that the spring gets The spring operated recharged immediately after closing.
automatically
Imploding type surge suppressor and earthing truck with full capacity circuit breaker, three (3) Nos. single phasee PT, selector switch and test plugs shall be considered at the outgoing side of VCB. Both incoming and outgoing terminals of VCB shall be suitable for terminating 33 kV (E) grade XLPE insulated PVC sheathed, 3core, aluminium conductor condu cables.
The circuit breaker shall be provided with necessary auxiliary switches for indication, control, interlocking, protection and alarm. Six spare auxiliary contacts, three (3) NC and three (3) NO shall be left eft free in the breaker. All the contacts shall be wired to the terminal block. Space heaters to prevent moisture condensation within the enclosure shall be provided in relay and control cubicle. Heaters shall be suitable for operation operation from 230 V, AC 50 Hz, single phase supply.
Technical Specification:Sec-6, Electrical
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33kV Control and Relay Panel
One (1) set of relay and control panels consisting of two (2) feeders and PT complete with mimic buses, instruments, controls, indication, alarm annunciation relays and alarm facia and protection relays as required for the the 33 kV feeder for the proposed plant and as described below shall be provided. The mimic diagram shall provide single line representation of the 33 kV system. The control and relay panel shall be located inside the room for new 33 kV VCB panel.
The relay and control panel shall be floor mounted type, having sheet steel of 2.5 mm thickness. A equipment shall be mounted such that removal and replacement replacement may be accomplished individually without interruption of service to adjacent equipment. The relay and control panel shall have rear access.
Test devices shall be provided for C.T. circuits. CTs shall not be open circuited circuited during testing operation. Adequate illumination shall be provided inside each cubicle. CFL lamps suitable for 230 V, 50 Hz, single phase supply shall be provided. Potential circuits for suitable MPCB/MCB.
instrumentation and and for metering each shall be protected
by
Annunciator shall be suitable for 220 V DC operation. It shall have a single DC alarm common to all points. Space heaters to prevent moisture condensation within within the enclosure shall be provided in relay and control cubicle. Heaters shall be suitable for operation from 230 V, AC 50 Hz, single phase supply. A relay shall be numerical type having communication port conforming protocol as per IEC61850 for direct interfacing with plant
commun communication
PLC/DCS/SCADA system. Numerical relay shall be capable to receive minimum adequate nos. inputs and output contacts. (ACDB 415-240 V AC Distribution Board (ACDB) 415 V, 3phase, 4wire ACDB shall be provided which will be fed from the secondary side of 33/0.433kV auxiliary control transformer. The auxiliary transformers shall be tapped from before the incoming HT circuit breakers over HT load break isolator, HRC fuse and voltmeter. The distribution board shall be provided with two incoming feeders, each comprising one MCCB and one magnetic contactor connected to one common comm set of busbars. ACDB shall be floor mounted, totally enclosed, fully compartmentalised, multitier single Technical Specification:Sec-6, Electrical
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front design. The distribution board shall be suitable for cable entry from the bottom. Devices requiring operation shall shall be located in between 450 mm and 1900 mm from the floor level . The ACDB shall have indicating voltmeter with selector switch, PT, MPCB & MCB at the line side of the distribution board. Ammeter with selector switch, CT, MPCB & MCB shall also be provided. These instruments shall be flush type located on the front door of the compartments. The sizes of ammeter and voltmeter shall be 96 mm x 96 mm. Phase indicating lamps shall be provided vided at the bus side of incomer. The ACDB shall be fabricated from minimum 2.0 mm thick CRCA sheet steel with load bearing members comprising 2.5 mm thick CRCA sheet steel. The degree of protection shall be IP:54. A the outgoing feeders shall be of MCCB/MCB unit. Power circuit isolation shall be possible without opening the front door and shall have provision for padlocking in OFF position with the door closed. ON/OFF indications shall be provided for a feeders by means of cluster LED lamps. The main phase busbars and tappings shall be made of aluminium having cross sectional areas to be substantiated during engineering engineering but in no case the current density shall be more than 80 A/sq cm. The busbars shall be suitably supported on non hygroscopic moulded glass reinforced plastic insulators so as to be capable of withstanding withstand dynamic forces due to 50 kA through fault short circuit. All joints shall be coloured PVC taped. Temperature rise of busbars/joints while carrying the rated current shall not be more than 45°C over maximum ambient ambient temperature of 45°C when measured by thermometer. Tappings from the main busbars to individual feeder compartments shall be by means of insulated single core copper cables with stranded conductor for feeders upto 100 A ratings above which aluminium busbars shall be used. All copper to aluminium joints shall be provided with bimetallic nuts/bolts/washers. A continuous 50 mm x 10 mm aluminium earth bus shall be provided throughout the length gth of the panels and shall be located in a separate chamber at the bottom with removable front cover. Provision shall be kept for taking earth connections to external earth mat. PVC insulated (Green coloured) copper wires shall shall be used to connect all noncurrent carrying metallic parts, doors, etc to the earth bus. All relays, instruments, meters, pushbuttons, switches and other devices of any feeder shall be located on the respective compartment only. All operating handles, control switches, pushbuttons, indicating lamps, instruments, meters etc shall be mounted on the front of the cubicles.
220 V DC Control Battery Bank Battery bank shall consist st of plante type lead acid cells in transparent plastic containers with sufficient quantity of electrolyte, acid level indicating floats, intercell connectors, cell support insulators, cell number plates, properly treated treated and acid resistant painted wooden stand supported on porcelain insulators, terminal connectors for external connections etc. as required to make the installation complete in all respects. The wooden Technical Specification:Sec-6, Electrical
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stands shall be made of good quality teak wood suitably treated with two coats of linseed oil and three coats of antisulphuric acid paint. coated Inter row and intertier connectors for the batteries shall be made of copper with lead. The terminals of each cell shall be indelibly identified for polarity. The terminals of battery outgoing leads shall have provision for connecting lead coated copper bars which shall be suitably extended upto the room wall for termination of external aluminium conductor, XLPE insulated cables. Suitably terminals shall also be provided for taking takin external connections from cell by aluminium conductor XLPE insulated cables. The cells shall be delivered in dry and discharged condition. Sufficient quantity of electrolyte ready to fill condition shall be supplied for the the first filling of the batteries in nonreturnable airtight plastic/polypropylene containers. Ten (10) percent extra electrolyte shall also be provided.
Complete battery maintenance equipment required for convenient convenient and safe handling and preparation of electrolyte shall be supplied with the battery bank. These shall include but not be limited to items like syringe type hydrometer, mercury in glass thermometer calibrated 0 to 100o C, wall mounted holder for one hydrometer and one thermometer, syringe, level testing tube, 150 mm dia glass funnel, spanners, centre zero cell testing voltmeters, PVC gloves, gl PVC jug, etc. Load Break Switch (LBS) Load break switch panel shall consist of the following: 33 KV, 31.5 KA rated HT air break/load break switch suitably interlocked with earth switch shall be provided. It shall be with front operated spring assisted assisted manual mechanism with 2 N/O and 2 N/C auxiliary contacts. It shall contain: ON/OFF indication lamp – 2 Nos. Suitably rated copper busbar – 1 set Space heater with thermo start and switch control Mechanical interlocks Provision of receiving incoming coming 33 KV XLPE cable at bottom. Ring Main Gear (RNG): The ring main gear shall be indoor type and shall consist of one No. 33 KV suitably rated, short rating 31.5 KA, load breaks switch with interlocked earth switch front operated spring assisted manual closing mechanism horizontal draw out, horizontal isolation VCB fitted with motor operated charging mechanism for controlling the outgoing supply. Rated voltage – 33 KV Rated Current- as per requirement Frequency – 50 Hz Cubicle – Floor mounted free fr standing dust and vermin proof. Technical Specification:Sec-6, Electrical
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Encl: IP-45 Control voltage – 220 V DC
BELT SWAY SWITCH The belt sway switch shall be shall be auto reset type and provided at both ends and at an interval of 50 mtrs (for conveyor length greater that 200 mtrs) on both sides of conveyors and also before and after belt weighing system on both sides. It shall be of auto reset type. The belt sway switch shall be industrial heavy duty type housed in dust and vermin proof box with degree of protection IP-54. IP 54. The switch shall be designed that conveyor does not come in direct contact with the switches and mechanism shall have strong rest spring to absorb high impact of loaded belt edge. The switch element shall be self rest type and shall have 2NO+2NC contacts each rated for 10A, 240V AC. It shall be suitable for ambient temp. of 600C. Resetting spring mechanism, built in terminal box, actuating ctuating rollers, roller shafts, supporting frame, etc shall be provided as per requirement. Belt sway switch shall be J&N make. PULL CHORD SWITCH Pull chord switches shall be auto reset type industrial heavy duty enclosed in dust and vermin proof enclosure with degree of protection IP-65. IP 65. They shall be provided with following facilities; • Switch elements shall be 2NO+2NC each rated for 10A, 240V AC. • Automatic locking arrangement in the operated position with manually reset • Snap action type for positive posi operation of contacts • Number of position shall be 1-0-1 1 • Separate compartment for built in terminal box • Suitable base plate Pull rope shall be stranded galvanized steel wire with at least 1 mm thick PVC cover and having overall diameter of 6mm to 7mm. 7mm. Pull rope switch shall be placed at an interval of 25 mtr on both sides of conveyor with minimum of one pair for conveyor length less than 25 mtr. ZERO SPEED SWITCH The unit shall be provided with MS flags, sensing probes, monitoring unit and interconnecting inte special cables. The unit shall be of multi speed range with setting facility and shall be provided with output contacts (2NO+2NC) with facility for initial bypass adjustable time delay, nuisance tripping delay and analog/digital speed display. 4-20mA 20mA isolated DC signal shall be applicable for external metering. Sensing probe shall be provided with metallic enclosure of degree of protection IP-67 67 and LED lamp for visual indication of correct functioning of sensing probe.
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PASSIVE FIRE PROTECTION Fire protection for cables at entry/exit points of the wall shall be provided with proper sealing by fire sealing material. The fire sealing compound shall be rated for minimum 2 Hours. Fire retardant painting shall also be provided on cables for 2 Mtrs on both sides of the wall/floor crossing. ERECTION & INSTALLATION ACCESSORIES All cable accessories like conduits, inserts, cable tag markers, clamps, sealing compound, pull boxes, marshalling boxes etc. shall be considered as part of the Bidders scope scop to complete the erection job in all respect. OTHER ITEMS Bidder shall provide all required switches, cabling and other devices needed for proper control, operation, interlocking and sequencing of the any other offered systems and technological mechanism, if specified in technological, e.g. hanging magnets and wipers wi (if applicable), roof exhaust fans & wall exhaust fans (if applicable), etc. All required safety items like rubber mats in front of MCC/DB/Panel, shock treatment chart, first aid boxes, danger boards, boards indicating 'Man on Work, Do not switch ON', ON 'Do not switch OFF', 'EARTHED' etc. shall be provided in each electrical premises. Wall mounted aux. AC and DC distribution boards shall be provided in sufficient number to facilitate proper distribution of the power supply to various users. Bidder to include closing of all cable and panel openings through a Fire sealing material. This shall include closing of all bottom opening of control room panels/desks, MCC switch boards, wall openings in all the areas, etc. Bidder shall also include earthing of all equipments/system, wherever required, under his scope of supply. Bidder shall include painting of all the plant and equipment with approved shades and include primers as well as finishing paints. Sufficient quantity of GI ladder type factory fabricated fabricated cable trays made from 2.5 mm thick hot welded steel sheets grade ‘o’ as per IS: 2062 shall be provided. Hot dip galvanizing of 85 micron thick as per IS-2629, 2629, IS-4759 IS and IS- 209. Trays shall be of standard length of 3 m with max deflection not exceeding ding 1/400 of span with sufficient load bearing capacity. 4.16 ERECTION OF ELECTRICAL EQUIPMENT Bidder shall include erection of all the equipment under his scope of supply. Erection of equipment shall have to be carried out as follows:
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1. Procedure mentioned in manufacturer’s manual 2. Under the expert supervision 3. Sequence and plan of erection as per the guidance of Purchaser’s Site In charge or their consultant 4. During erection of supplier’s equipment, existing equipment /system shall not be disturbed. 5. Erection shall be in accordance with approved layout drawing and installation details. 6. Cable laying shall be as per approved cable layout drawings and work shall be carried out in a neat manner. installation accessories required for erection/installation erection/installation of equipment and All erection-installation handling equipment required for handling of equipment from store to installation site are included in the scope of work of Bidder as a whole. Bidder shall ensure that the work erection and erected equipment shall comply with wit all statutory norms, regulations and standards applicable to the works/equipment and any additional work/equipment required, if any, shall be under scope of the Bidder. Necessary clearance from the wall shall be maintained as per IS/IE Rules from front/rear/ front/ side of all the panels inside a room. HT Power cables and LT power/control cables shall be laid in different cable trays. LT power cables and LT control cables shall also be laid in different trays, however, if necessity arises due to space constraints ints or lesser number of cables, LT power cables and LT control cables can be put on the same trays keeping sufficient gap between them. 24V DC cables, if required, shall be laid entirely in different dedicated trays. Cable trays in single tier or in multitier multitier shall be installed in vertical arrangement everywhere to avert coal accumulation and space reduction.
Fire Prevention:Proper design and use of quality material, equipment so as to avoid overloading in Distribution board, wiring system including sub main, switch & sockets shall be ensured by the bidder. Insulating mats in front of PCC, MCC or control panel, protective rubber gloves, earth rods, artificial respiration apparatus, line man’s belt etc shall be provided in substations by the bidder. re extinguishers for various switch gear location, substations, PCC, MCC suitable for Fire electrical fire (class –C) C) like dry chemical powder, carbon-dioxide, carbon dioxide, carbon-tetra carbon chloride type shall be provided along with fire buckets filled with sands. Comprehensive fire protection system in conformity with the requirements of national building code, ECBC 2007 shall be ensured by the bidder. 5.0
INSPECTION AND TESTING
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5.1 Inspection Extent of inspection The extent of inspection & testing by the Purchaser shall vary from equipment to equipment as per design requirements. However, indicative extent of inspection for electrical equipment is furnished below: Extent of inspection to be carried out shall be finalised with the Contractor after award of the contract on the basis of scope of supply, technical specification and approved GA drawings. However, in case of similar bulk manufactured items, methods of sampling for inspection of different lots shall be governed by relevant Indian or international international standards. In case of critical components, the Purchaser reserves the right to undertake 100% inspection. Final inspection & testing shall be done as per the following: • Verification of test certificates • Visual, Workmanship & painting • Dimensional • Witnessing of routine/acceptance/type/special tests as per relevant standards. • Witnessing of proto-type type tests, as applicable • Verification of type test certificates for identical equipment • Approved QAP The inspection shall be carried out on the basis of QAP dully approved by Purchaser / consultant.
INSPECTION CATEGORIES All the electrical equipment have been classified in three categories for inspection and issuing dispatch clearance by the Purchaser/consultant. The three categories are:
Category-A All the tests shall be inspected by the Purchaser/Consultant. Dispatch clearance shall be given by Purchaser/Consultant haser/Consultant after the equipment is inspected and found as per requirement and as per TS. All types tests certificates shall e submitted by the Bidder in this case. Category-B Inspection shall be carried out by prime bidder and inspection waiver certificate certificate shall be issued by Purchaser/Consultant based on type test certificates and routine tests certificates furnished by the Bidder. Purchaser/Consultant shall issue dispatch clearance accordingly. Category-C
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Dispatch clearance shall be given by Prime bidder without any certificates based on technical data sheet furnished by the Bidder.
5.2
S. N.
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
HT CABLE LT MOTORS LT POWER AND CONTROL CABLES MCC TRANSFORMER PLC & CONTROL DESK UPS ON LOAD 33 kV ISOLATOR TRAILING CABLE / FLEXIBLE (EPR) CABLE PDB/LDB/SLDB/AUX. PDB SIGNAL, INSTRUMENTATION AND OTHER SPECIAL CABLES CABLE ACCESSORIE LIGHT FITTINGS EARTHING AND LIGHTNING PROTECTION MATERIALS FIRE SEALING MATERIALS LOCAL PUSH BUTTON STATIONS POWER SOCKET CABINET AND LIGHTING CABINET CONTROL AND RELAY PANEL 415V FEEDER PILLAR 33KV VCB LT DISTRIBUTION BOARD 33KV LIGHTENING ARRESTER 33KV ISOLATOR AND EARTH SWITCH 33KV CT,PT BATTERY,BATTTERY CHARGER,DCDB FIRE EXTINGUISHER JB,RUBBER MAT,DANGER BOARD,FIRE BUCKET,FIRST AID BOX,HAND GLOVES,SHOCK TREATMENT CHART,DISCHARGE ROD.MEGGAR
INSPECTION CATEGORY A B B A A A A A A B B C C C C B B A A A A B B B A C C
Testing General Test of all equipment shall be conducted as per latest BIS. Wherever no such standard exists, tests shall be as per International Standards like IEC/DIN/BS/IEEL/JIS, etc. All routine tests shall be carried out at manufacturer's works in presence of Purchaser or his representative.
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The Bidder shall submit type test certificates (not more than 5 years old) for similar equipment supplied by him elsewhere. In case type test certificates certificates for similar equipment is not available, the same shall be conducted in presence of Purchaser or his representative, without any financial implications to Purchaser. The Bidder shall be responsible for satisfactorily working of complete integrated integr system and guaranteed performance. Site Tests and Checks General All the equipments shall be tested at site to know their condition and to prove suitability for required performance. The test indicated in following pages shall be conducted after installation. All tools, accessories and required instruments shall have to be arranged by contractor. Any other test which is considered necessary by the manufacturer of the equipment, contractor or mentioned in commissioning manual has to be conducted at a site. In addition to tests on individual equipment, some tests/checks are to be conducted / observed from overall system point of view. Such checks are highlighted under miscellaneous tests but these shall not be limited to as indicated and shall be finalized finalized with consultation of client before charging of the system. The contractor shall be responsible for satisfactory working of complete integrated system and guaranteed performance. All checks and tests shall be conducted in the presence of client’s client’s representative and test results shall be submitted in six copies to client and one copy to Electrical Inspector. Test results shall be filled in proper Performa. After clearance from Electrical Inspector system/ equipment shall be charged in step by step method. Based on the test results clear cut observation shall be indicated by testing engineer with regard to suitability for charging of the equipment or reasons reasons for not charging are to be brought by the contractor. Trial Run Test After the successful test of each equipment as per standard test procedure the entire control system shall be put on trial run test on actual site conditions and operation of the system. sy Acceptance Test
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The acceptance test on the system shall be carried out by the supplier as per mutually agreed test procedures to establish satisfactorily functioning of the system as a whole and each equipment as part of the system. Site Tests The tests to be carried out on the equipment at pre-commissioning pre commissioning stage shall include following but not limited to the following: MCC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
IR test before and after HV test. HV test with 2.5 kV megger Functional test for all feeders Testing and calibration of all meters Checking and calibration of protective relays as per supplier's commissioning manuals Check operation of contactors from local and remote points Checking of interlockings between incomers/bus coupler and other feeders. Test to prove interchangeability of similar parts Tests to prove correct operation of breakers at minimum and maximum specified control voltages Checking of earthing connection for fo neutral-earth earth bus, cable armour, location of E/F CT etc. as per the scheme. Check test, service and drawout position of all the breakers and operations of mechanical flag indicator and electrical indication lamps. Check functioning of various elect. schemes schemes like autochangeover signalling etc. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and between phases in off position
MOTORS 1. IR test of stator and rotor windings. 2. Ensure that checking/testing of associated switchboard, switchboard, cables, relays /meter interlocks as mentioned in relevant are completed. 3. Check tightness of cable connection 4. Winding resistance measurement of stator and rotor. 5. Checking continuity of winding. 6. Check tightness of earth connections. 7. Check space heaters and carryout heating of winding (if required) 8. Check direction of rotation in de-coupled de coupled condition during kick start 9. Measure no load current for all phases. 10. Measurement of temperature of body during no load and load conditions. 11. Check for tripping of motor from local/remote switches and from electrical/technological protection. 12. Checking of vibration 13. Checking of noise level 14. Shaft voltage measurement (if required) 15. Tan delta test, if required Technical Specification:Sec-6, Electrical
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16. During load running, measurement of stator and bearing temperatures (if applicable) for every half an hour interval till saturation comes. 17. Checking tightness of foundation bolts 18. Check operation of speed switch (if there) 19. Check continuity of temp. detectors. 20. Check alignment, paralleling of of shafts, level of lubricating oil etc. as per manufacturer's manual 21. Check for polarisation index of stator winding, R10/R1 by motorised megger (The value should not be less than 2.0). R60/R10 absorption co-efficient co efficient shall not be less than 1.5. TRANSFORMER IR test on each winding to ground and between windings. 1. 2. Turns ratio test on each tap 3. Polarity and vector group test 4. Measurement of winding resistance by Kelvin bridge 5. IR, wiring and operational tests on all control devices in control cabinet, cabi oil level indicator, winding and oil temp. indicators etc. 6. Checking of earthing wrt transformer tank (flexible from top cover to tank) other parts, neutrals. 7. Testing of buchholz relay for alarm and trip conditions. 8. For bushing CTs, tests applicable shall be as for current transformers. 9. Setting of oil/winding temperature indicators, level gauge and checking of alarm/trip circuits. 10. Check insulators for cracks. 11. Checking for oil leakage and arresting of leakages (if there) t 12. Checking of operation of all valves. 13. Checking for open position of all the valves (except drain and filter valves) 14. Filtration of oil by using line filter, vacuum pump, and heater set. 15. BDV test on oil samples from top and bottom. 16. Checking of oil for acidity, water content tan delta etc. as per IS 335. 17. Measurement of magnetising current and no load loss. 18. Measurement of PI value. 19. Checking of silica gel breather. 20. Checking of noise level at no load and at full load. 21. Checking of air circulation conditions c for indoor transformers. 22. Conducting magnetic balance test 23. Checking of other points given in manufacturer's commissioning manual. 24. Frequency response analysis for HT transformers (at manufacturer’s works) UNINTERRUPTED POWER SUPPLY (UPS) 1. Visual check IR value by megger 2. 3. Current limit test 4. Ripple test 5. Supply variation Technical Specification:Sec-6, Electrical
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6. 7.
Functional test Capacity test wrt time
PDB/LDB/SLDB/AUX.PDB 1. IR test before and after HV test. 2. HV test with 2.5 kV megger 3. Functional test for all feeders 4. Testing and calibration of all meters 5. Checking and calibration of overload relays and protective relays as per supplier's commissioning manuals. 6. Check operation of contactors from local and remote points 7. Checking of interlockings between incomers/bus coupler coupler and other feeders. 8. Test to prove interchangeability of similar parts 9. Tests to prove correct operation of breakers at minimum and maximum specified control voltages neutral earth bus, cable armour, location of E/F E/ CT 10. Checking of earthing connection for neutral-earth etc. as per the scheme. 11. Check test, service and drawout position of all the breakers and operations of mechanical flag indicator and electrical indication lamps. 12. Check functioning of various elect. schemes like autochangeover signalling etc. 13. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and between phases in off position CABLES & CABLE SUPPORTING STRUCTURES 1. Checking of continuity/phasing and IR values for all the cables before and after HV test. 2. Checking of earth arth continuity for armour. 3. Check for mechanical protection of cables. 4. Check for identification (tag number system) distance placement of cable marker, cable joint etc. as per the cable layout drawing. 5. Check earthing of cable structures. 6. Check clearances ces from light fittings for cable structures 7. Check proper fixing of cable structures. 8. Check for proper drainage and removal of water from cable trenches
EARTHING & LIGHTNING PROTECTION 1. Check tightness of all earth connections 2. Check earthing of all metallic equipment, cable trays, busbar supporting structures, all elect. equipments, etc. as per the requirement of IE rules and IS 3043 3. Measurement of earth resistance for each electrode. 4. Measurement of total earth resistance. 5. Measurement easurement of earth loop resistance for E/F path of biggest LT drive. ILLUMINATION 1. Lux level measurement in each area/premise 2. Test for black spot, if any Technical Specification:Sec-6, Electrical
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3. Check operation of complete lighting system MISCELLANEOUS 1. Checking of continuity of the system 2. Checking hecking safe accessibility of all operating points 3. Ensure availability of first aid box, rubber glove, etc. 4. Check for safe movement of operators to pump house w.r.t. proper illumination, light, uncovered openings, etc 5. Placement of shock treatment chart, danger boards, provision of boards indicating Man on Work, Do not switch ON', 'Do not switch OFF', 'EARTHED' etc. 6. Check proper dressing of cables, mechanical protection of cables, placement of cable markers 7. Check sealing of all cable openings including conduit opening with fire resistance material 8. Check sealing of all openings at bottom of panels
9.
Check proper road crossing of cables/earthing materials. LIST OF IMPORTANT INDIAN STANDARDS
SN
IS Standard with Latest Amendment 1 IS : 732 – 1989
Title Code of practice for electric al wiring installations.
2 IS: 4648 – 1968
Guide for electrical layout in residential buildings.
3 IS : 8081 – 1976
Code of practice for design, installation and maintenance of service lines upto and including 650 V.
4 IS : 8884 – 1978
Code of practice for installation of electrical bells and call system.
5 IS: 5578 – 1985 6 IS : 11353 – 1985
Guide for marking of insulated conductor. Guide for uniform system of marking and identification of conductors and apparatus terminals.
7 IS: 5728 – 1970 8 IS:7752(Part 1) – 1975
Guide for short-circuit calculations. Guide for improvement of power factor in consumer installation : Low and medium supply voltages.
9 IS:3646(Part 1) – 1966
Code of practice for interior illumination : Principles for good lighting and aspects of design.
10 IS:3646(Part-3) – 968
Code of practice for interior illumination: Schedule of illumination and glare index.
11 IS:3646(Part-3)-1968
Code of practice for interior illumination: Calculation of coefficients of utilization by the BZ method.
12 IS:4347 – 1967
Code of practice for hospital lighting.
Technical Specification:Sec-6, Electrical
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SN
IS Standard with Latest Amendment 13 IS:6665 – 1972 14 IS:2672 – 1966 15 IS:10118(Part 1) – 1982
Title Code of practice e for industrial lighting. Code of practice e for library lighting. Code of practice for selection, installation and maintenance of switchgear and control gear; General
16 IS:10118(Part-2)-1982 1982
Code of practice for select ion, installation and maintenance of switchgear and control gear selection.
17 IS:101118(Part-3)-1982 1982
Code of practice for select ion, installation and maintenance of switchgear and control gear Installation.
18 IS:10118(Part 4) - 1982
Code of practice for select ion, installation and maintenance of switchgear and control gear selection.
19 IS:4146 – 1983 20 IS: 4201 – 1983 21 IS:5547 – 1983
Application guide for voltage transformers. Application guide for current transformers. Application guide for capacitor voltage transformers.
22 IS:2309 – 1989
Code of practice for the protection and allied structures against lightening
23 IS:3043 – 1987 24 IS:5216(Part01) – 1982
Code of practice for earthing. Guide for safety procedures and practices in electrical work : General.
25 IS: 5216(Part 1) – 1982
Guide for safety procedures and practices in electrical work : Life saving techniques.
26 IS:3696(Part-2) – 1966
Safety code for scaffolds and ladders: Ladders Electric fans.
27 28 29 30
IS: 555 – 1979 IS:1169 – 1967 IS:374 – 1979 IS:2997 – 1964
Electric table type fans and regulators. Electric pedestal type fans and regulators. Electric ceiling type fans and regulators. Air circulator type electric fans and regulators.
31 32 33 34 35 36 37 38
IS: 2312 – 1967 IS:3588 – 1987 IS:3963 1987 IS:4283 – 1981 IS:6272 – 1987 IS:4894 – 1987 IS:11037 0 1984 IS:12155 – 1987
Propeller type AC ventilating fans. Electrical axial flow fans. Roof extractor units. Hot Air fans. Industrial cooling fans (man coolers) Centrifugal fans. Electronic type fan regulators. General and safety requirements for fans and regulators for house hold and similar purposes, Low voltage switch gear and control gear.
Technical Specification:Sec-6, Electrical
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SN
IS Standard with Latest Amendment SWITCH GEAR
Title
39 IS:4237 – 1983
General requirements for switch gear and control gear for voltages not exceeding 1000 V ac or 1200v dc
40 IS:675(Part-1) – 1973
Control Switches (switching devices for control and auxiliary circuits including contractor (relays) for voltages upto and including 1000 v AC and 1200 v DC:
41 IS:6875(Part2) – 1973
Control Switches (switching devices for control and auxiliary circuits including contractor (relays) for voltages upto and including 1000 v AC and 1200 v DC:
42 IS:6875(Part-3)-1980
Control Switches (switching devices for control and auxiliary circuits including ncluding contractor (relays) for voltages upto and including 1000 v AC and 1200 v DC:
43 IS:10027-1981
Composite unit o air break switches and rewireble type fuses for voltages not exceeding 50 V AC.
44 IS:4064(Part 1) -1978 1978
Air break switches, air break disconnectors, air break switch disconnectors and fuse combination units for voltages not exceeding 1000 v AC or 1200 v AC : General requirements.
45 IS:2675 – 1983
Enclosed distribution fuse boards and cutouts for voltages not exceeding 1000 V.
46 IS:8828 – 1978
Miniature air break circuit breakers for voltages not exceeding 1000 volt.
47 IS: 13032 – 1991
Miniature circuit breaker boards for voltages upto and including 1000 volts AC.
48 IS:12640 – 1988 49 IS:2959 – 1985
Residual current operated circuit breakers. Voltages not exceeding 1000 v AC or 1200 v DC.
50 IS:2516(Part01/Sec 1 – 1985
Circuit breakers: Requirements and tests: Voltages not exceeding 1000 v AC or 1200 v DC.
51 IS:12021 – 1987
Specifications for control transformers for switch gear and control gear for voltages not exceeding 1000 volts AC.
52 IS:5039 – 1983
Distribution pillars for voltages not exceeding 1000 V.
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SN
IS Standard with Latest Amendment 53 IS:8623 (Part 1) – 1977
Title Factory built assemblies of switch gear and control gear for voltages up to and including 1000 v AC and 1200 v DC : General requirements.
54 IS:8623 (Part 2) – 1980.
Factory built assemblies of switch gear and control gear for voltages up to and including 1000 v AC and 1200 v DC : Particular requirements for bus bar trunking system (busways)
55 IS:8544(Part 1) – 1977
Motor starters for voltages not exceeding 1000 v : Direct on line AC starters.
56 IS:8544(Part 2) – 1977
Motor starters for voltages not exceeding 1000 v : Star-delta starters.
57 IS:8544(Part 4 ) – 1979
Motor starters for voltages not exceeding 1000 v: Reduced voltage ac starters, two step auto transformer starters.
POWER CABLE 58 IS:694 – 1990
PVC insulated cables for working voltages upto and including 1100 V.
59 IS:1554(Part 1) -1988 1988
PVC insulated (heavy duty) electric cables: For working voltages upto and including 1100 v.
59 IS:3961 (Part 5) – 1968
Recommended current ratings for cables: PVC insulated light duty cables.
60 IS:4288 - 1983
PVC insulated (heavy duty) electronic cables with solid aluminum conductors for voltages up to and including 1100 v
60 IS:4289(Part 1) – 1984
Flexible cables for lifts and other flexible connections: Elastomer insulated cables.
Electrical Wiring Accessories 61 IS:9537(Part 1) – 1980
Conduits for requirement.
electrical
installations:
General
62 IS:9537(Part 2) – 1981
Conduits for electrical installations: Rigid steel conduits.,
62 IS: 3480 – 1966 63 IS:2667 – 1988
Flexible steel conduits for electrical wiring. Fittings for rigid steel conduits for electrical wiring.
63 IS: 3837 – 1976
Accessories for rigid steel conduits for electrical wiring.
64 IS:9537 (Part 4) – 1983
Conduits for electrical installations: Pliable self recovering conduits of insulating materials.
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SN
IS Standard with Latest Amendment 64 IS:6946 – 1973
Title Flexible (pliable) non-metallic metallic conduits for electrical installations.
65 IS:3419 – 1989 65 IS:5133 (Part-1) – 1969
Fittings for rigid non-metallic conduits. Boxes for enclosure of electrical accessories: Steel and cast iron boxes.
66 IS:5133 (Part 2) – 1969
Boxes for enclosure of electrical accessories
66 67 67 68 68 69
Link clips for electrical wiring. Ceiling roses. Switches for domestic and similar purposes. Switch socket outlets (non-interlocking interlocking type). Interlocking switch socket outlet. Plugs and socket outlets of rated voltage upto and including 16 amperes.
IS:2412 – 1975 IS: 371 – 1979 IS: 3854 – 1988 IS: 4615 – 1968 IS:4160 – 1967 IS:1293 – 1988
Electric Lamps and their Auxiliaries 70 IS: 418 – 1978
Tungsten filament general service electric lamps.
71 IS:2418 (Part 1 ) – 1977
Tubular fluorescent lamps for general lighting service : Requirements and tests.
71 IS: 990(Part 1) – 1981
High pressure mercury vapor lamps: Requirements and tests.
72 IS:9974(Part 1) -1981 1981 72 73 IS: 1258 – 1987 73 IS: 3323 – 1980
High pressure sodium vapor lamps : General requirements and tests. Bayonet lamp holders. Bi-pin pin lamp holders for tubular fluorescent lamps.
74 IS: 3324 – 1982
Holders for starters for tubular fluorescent lamps.
74 IS: 2215 – 1984 75 IS: 1534 (Part 1) – 1977
Starters for fluorescent lamps. Ballast for fluorescent lamps: For switch start circuits.
75 IS: 1569 – 1976
Capacitors for use in tubular fluorescent high pressure mercury and low pressure sodium vapor discharge lamp circuits.
76 IS:6616 – 1982
Ballasts for high pressure mercury vapor lamps. Light fittings and luminaries.
76 IS: 1913 (Part 1) – 1978
General and safety requirements for luminaries Tubular fluorescent lamps.
77 IS: 10322 (Part 1 ) 1982 77 IS: 10322(Part 2) - -1982 1982 78 IS: 10322 (Part5 / Sec 1 ) 1987
Luminaries : General requirements. Luminaries : Constructional requirements. Luminaries : Particular requirements: Recessed luminaries
Technical Specification:Sec-6, Electrical
Page 90 of 97
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IS Standard with Latest Amendment 78 IS:10322 (Part 5 / Sec. 3) 1987
Luminaries : Particular requirements: luminaries for road and street lighting.
79 IS:10322 (Part 5 / Sec.4) – 1987
Luminaries : Particular requirements: luminaries for road and street lighting.
79 IS: 10322(Part 5 / Sec 5) 1987
Luminaries : Particular requirements: Flood lights.
80 IS: 3287 – 1965
Industrial lighting fittings with plastic reflectors.
81 IS: 2206 (Part 1) – 1984
Flame proof electric lighting fittings : Wall glass and bulk head types.
82 Is:3528 – 1966 83 IS: 3553 – 1966 84 IS: 9030 – 1976 85 IS: 7537 – 1974 86 IS: 9583 – 1981 87 IS: 9583 – 1981 Electric Appliances 88 IS: 6236– 1971 89 IS: 1248 (Part 1) – 1983
Title
Water proof electric lighting fittings. Water tight electric lighting fittings Luminarires for hospitals. Road traffic signals. Emergency lighting units. Emergency lighting units. Direct recording Direct acting indicating analogue electrical measuring instruments and their accessories: General requirements.
90 IS:1248 (Part 2) – 1983
Direct acting indicating analogue electrical measuring instruments and their accessories: Ammeters and voltmeters.
91 IS:1248 (Part 3) – 1983
Direct acting indicating analogue electrical measuring instruments and their accessories: Wattmeters and Varmeters.
92 IS: 1248 (Part 3) – 1983
Direct acting indicating analogue electrical measuring instruments and their accessories: ssories: Frequency meters.
93 IS: 1248 (Part 5) – 1983
Direct acting indicating analogue electrical measuring instruments and their accessories: Phase meters, power factor meters and synchronoscope.
94 IS: 722 (Part 1) – 1988
AC electricity meters: General requirements and tests.
95 IS: 722 (Part 2) - 1977
AC electricity meters: Single-phase phase whole current watt hour meters, class 2.
96 IS:722 (Part 3) – 1977
AC electricity meters: Three phase whole current and transformer operated and single phase transformer operated watt hour meters, class 2.
Technical Specification:Sec-6, Electrical
Page 91 of 97
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IS Standard with Latest Amendment 97 IS: 722(Part 5) – 1980
Title AC electricity meters: Volt-ampere ampere hour meter for restricted power factor range : General requirements.
98 IS:722 (Part 7)/Sec.1 - AC electricity meters : Volt-ampere ampere hour meter for 1987 full power factor range: General requirement 99 IS: 722 (Part 8) 1972
AC electricity meters: Single phase 2 wire whole current watt-hour meter (Class 1.0).
100 iS: 722 (Part 9) 1972
AC electricity meters: Three phase whole current and transformer operated Watt-hour hour meters, and single phase two wire transformer operated watt-hour watt meters (Class 1.0).
101 IS: 8530 – 1977 102 IS: 2992 - 1987 Instrument Transformers 103 IS: 2705 (Part 1) -1981 1981 104 IS: 2705 (Part 2) -1981 1981
Maximum demand indicators. Insulation testing testers Current transformers: General Requirement Current transformers: Measuring transformers.
105 IS: 2705 (Part 3) -1981 1981
Current transformers: transformers.
106 IS: 2705 (Part 4) -1981 1981
Current transformers: Protective current transformers for specific purpose applications.
107 IS:6949 – 1973
Summation current transformers.
Fuses 108 IS: 9224 (Part 1 ) – 1979 109 IS: 9224 (Part 2 ) – 1979
Protective
current current
Low voltage fuses : General requirements. Low voltage fuses : Supplementary requirements for fuses for Industrial applications.
110 IS: 2086 – 1982
Carriers and bases used in rewireable type electrical fuses upto 650 volts.
111 IS: 9926 – 1981
Fuse wire used in rewireable type electric fuses upto 650 volts.
112 IS: 8187 – 1976 Miscellaneous 113 10000/1980/Pt.1to12 114 10028/Pt.1/1985
Technical Specification:Sec-6, Electrical
D – Type fuses Methods of tests for IC Engines Code of Practice for Selection ,installation & maintenance of Transformers - Selection
Page 92 of 97
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IS Standard with Latest Amendment 115 10028/Pt.2/1981
Title Code of Practice for Selection ,installation & maintenance of Transformers - Installation
116 10322/Pt.3/1984
Specification for Luminaries :Screw & Screw less Terminals
117 10322/Pt.4/1984
Specification of Luminaries :Methods of Tests
118 10322/Pt.5/ Sec.2/1985
Luminaries :Particular Requirements : Portable general purpose Luminarie
119 1239/Pt.1/1990
Mild Steel Tubes ,Tubulars & other wrought Steel Fittings : Mild Steel Tubes
120 1239/Pt.2/1992
Mild Steel Tubes ,Tubulars & other wrought Steel Fittings : Mild Steel Tubulars and other wrought steel pipe fittings
121 1255/1983
Code of Practice for installation maintenance of power cables upto and including 33KV rating
122 12640/Pt2/2001
Residual Current Operated Circuit Breaker for household and Similar uses : Circuit Breakers with Integral Over Current Protection (RCVOs)
123 13118/1991
Specifications for High Voltage Alternating Circuit Breakers
124 1367/Pt.3/1991
Fasteners -Threaded steel -Technical Technical Supply Conditions - Mechanical Properties and test methods for bolts ,screws and studs with full load ability
125 1367/Pt.XIII/1983
Technical Supply Conditions for Threaded steel Fasteners --- Hot dip Galvanized coating on threaded fasteners
126 13925/Pt1/1998
Shunt Capacitors for ac power system having a rated voltage above 1000v : General performance ,testing rating safety requirements - guide for installation and operation
127 13925/Pt2/2002
Shunt Capacitors for ac power system having a rated voltage above 1000v : Endurance testing
Technical Specification:Sec-6, Electrical
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IS Standard with Latest Amendment 128 13947/Pt.1/1993
Title Specification for Low voltage switchgear and control gear - General Rules
129 13947/Pt.2/1993
Specification for Low voltage switchgear and control gear - Circuit Breakers
130 13947/Pt.3/1993
Specification for Low voltage switchgear and controlgear -Switches Switches ,Disconnectors ,Switch Disconnectors and Fuse combination Units
131 1445/1977
Porcelain insulators for overhead power lines with a nominal voltage voltage up to and including 1000 volts
132 1460/2000 133 14772/2000
Diesel Fuels : Specification General requirements for enclosures for accessories for house hold and similar fixed Electrical installations - Specification
134 135 136 137
Specification for plain washers Power Transformers :General Power Transformers :Temperature rise Power Transformers :Insulation Level and dielectric tests
2016/1967 2026/Pt.1/1977 2026/Pt.2/1977 2026/Pt.3/1981
138 2026/Pt.4 / 1977
Power Transformers :Terminal marking ,tappings and connections
139 2086/1982
Carrier and based used in rewireable type electric fuses for voltage up to 650 volts
140 2121/Pt.1/1981
Conductors and earthwire accessories for overhead power lines : Armour rods ,winding wires and tapes for conductors
141 2121/Pt.2/1981
Conductors and earthwire accessories for overhead power lines : Mid span jionts and repair sleeves for conductors
142 2268/1994
Electric call bells and buzzers for indoor use
143 2551/1982 144 2713/Pt.1 to 3
Danger Notice Plate Specifications for Tubular Steel Poles for overhead Power Lines
145 3043/1987 146 3419/1988
Code of Practice for Earthing Fittings for non metallic conduits
Technical Specification:Sec-6, Electrical
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IS Standard with Latest Amendment 147 3427/1969
148 3764/1992 149 3837/1976
Title AC Metal Enclosed Switchgear and controlgear for rated voltage Above 1kV and upto and including 52kV Code of Safety for excavation work Accessories for rigid steel conduits for electric wiring
150 3842/Pt1 to Pt.12/1967Pt.12/1967 Application guide for electrical Relays for ac system 1977 151 3854/1997
Switches for domestic and similar purpose
152 398/Pt.1/1976
Aluminium Conductor for Overhead transmission purpose : Aluminium stranded conductors
153 398/Pt.2/1976
Aluminium Conductor for Overhead transmission purpose : Aluminium conductors, galvanised steel reinforced
154 398/Pt.3/1976
Aluminium Conductor for Overhead transmission purpose :Aluminium conductors, aluminised steel reinforced
155 398/Pt.4/1994
Aluminium Conductor for Overhead transmission purpose : Aluminium alloy stranded conductors
156 398/Pt.5/1992
Aluminium Conductor for Overhead transmission purpose : Aluminium Conductor galvanised steel reinforced for extra high voltage
157 4540/1968
Monocrystalline semiconductor rectifier assemblies and equipment
158 4722/2001
Rotating Electrical Machines - Specifications
159 4794 (Pt.1)/1968
Push Button Switches -General General Requirement and test
160 4794 (Pt.2)/1986
Push Button Switches -Push Push Button Switches - type 1
161 5300/1969
Specification for Porcelain Guy Strain Insulators
162 5613/Pt.1/Sec.1/1985
Code of Practice for Design , Installation and Maintenance of over head power lines - Lines upto and including 11kV: Design
Technical Specification:Sec-6, Electrical
Page 95 of 97
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IS Standard with Latest Amendment 163 5613/Pt.1/Sec.2/1985
Title Code of Practice for Design , Installation and Maintenance of over head power lines - Lines upto and including 11kV: Installation and Maintenance
164 5613/Pt.2/Sec.1/1985
Code of Practice for Design , Installation and Maintenance of over head power lines - Lines above 11kV and upto and including 220kV: Design
165 5613/Pt.2/Sec.2/1985
Code of Practice for Design , Installation and Maintenance of over head power lines - Lines above 11kV and upto and including 220kV: Installation and Maintenance
166 5613/Pt.3/Sec.1/1989
Code of Practice for Design , Installation and Maintenance of over head power lines -400 kV Lines : Design
167 5613/Pt.3/Sec.2/1989
Code of Practice for Design , Installation and Maintenance of over head power lines - 400 kV Lines : Installation and Maintenance
168 6639/1972
Specification for Hexagonal bolts for steel structure
169 7098/Pt.1/1988
Crosslinked polyethylene insulated PVC sheathed cables : For Working voltage upto and including 1100 volts
170 7098/Pt.2/1985
Crosslinked polyethylene insulated PVC sheathed cables : For Working voltage from 3.3 kV upto and including 33kV
171 7098/Pt.3/1992
Crosslinked polyethylene insulated PVC sheathed cables : For Working voltage from 66 kV upto and including 220 kV
172 7935/1975
Insulator fittings for overhead power lines with a nominal voltage up to and including 1100 V
173 808/1989
Dimentions for Hot Rolled Steel Beam , column , Channel Angle Sections
Technical Specification:Sec-6, Electrical
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IS Standard with Latest Amendment 174 8623/Pt.3/1993
Title Specifications for Low Voltage Switchgear and Controlgear Assemblies : Particular requirements for Equipments Where unskilled Persons have access for their use
175 9537/Pt.3/1983
Conduit for Electrical Installation :Regid plain Conduits of insulating Materials
176 9537/Pt.4/1983
Specification for Conduit for Electrical Installations :Pliable self - recovering Conduits of insulating Materials
177 9537/Pt.4/1984
Specification for Conduit for Electrical Installations :Pliable Conduits of insulating Materials
178 9974/Pt.1/1982
High Pressure Sodium Vapour Lamps :Standard lamp data sheet
179 IS: 1885 (Part 1) - 1961
Electrotechnical definitions.
180 IS: 1885 (Part 9) 1966
Electro technical vocabulary: Electrical Relays.
181 IS: 1885 (Part 11) 1966
Electro technical Measurements.
182 IS: 1885 (Part 16) Sec 1) 1968
Electro technical aspects.
183 IS: 1885 (Part 16) Sec-2) Sec 1968
Electro technical vocabulary lighting: General illumination, lighting fittings and lighting for traffic and signaling.
184 IS: 1885 (Part 16/Sec.3) 1967
Electro Technical vocabulary Lighting: Lamps and Auxiliary apparatus.
185 IS: 1885 (Part 17 1979
Electro Technical vocabulary Lighting : Switch gear and control gear
186 IS: 1885 (Part 32 1971
Electro Technical vocabulary Lighting: Cables, conductors and accessories for electricity supply.
187 IS: 4770 – 1991 188 IS: 56424 – 1969
Rubber gloves for electrical purposes. Rubber mats for electrical purposes.
Technical Specification:Sec-6, Electrical
vocabulary
:
Fundamental
vocabulary:
vocabulary:
Lighting
Electrical General
Page 97 of 97
SECTION 7 (CIVIL) 1.0 1.1
1.2
GENERAL This section of the bidding document deals mainly with the technical specification needed for the design and preparation of detailed drawings, getting the design and drawings approved by the Engineer, fabrication, erection and construction of the necessary civil, structural tural and architectural works associated with the wagon Tippler plant.. The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries) and all other civil and structural works associated with the wagon Tippler Tip Plant. The specifications are intended for the general description of the work, quality and workmanship. The specifications are not, however, intended to cover minutest details and the work shall be executed according to the relevant latest Indian Standard Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be executed according to the best prevailing local Public Works Department practices or to the recommendations of relevant American and British Standards or to the the instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the Technical Specifications. The Contractor is expected to get clarified on any doubts about the specifications, etc. before bidding, in writing with the Employer in respect respect of interpretation of any portions of this document.
2.0
LAYOUT AND LEVELS
2.1
The layout and levels of all structures, etc. shall be made by the Contractor at his own cost from the general grid of the plot and bench mark given by the Engineer. He shall provide all instrument, materials and men to the Engineer for checking the layout and levels. However, the Contractor shall be fully responsible for correctness of layout and levels. The contractor has to mobilize well qualified survey team along with the survey equipment for day today survey work. They should use “Total Station” survey instrument for this purpose. The contractor has to setup his own laboratory to facilitate the checking of quality of civil works with equipments for checking of aggregate, aggregate, sand, concrete cube, etc. Area cleaning including jungle,rubbish,grass,trees etc are to be included in the scope of bidder.
2.2
2.3 2.4
3.0 3.1
3.2
3.3
DRAWINGS / DOCUMENTS The drawings included in the Bidding Document provide a general idea about the work to be performed under the scope of this contract. These are preliminary drawings for bidding purposes only and are by no means the final drawings or show the full range of the work under the scope. Work has to be executed according to drawings prepared by the contractor co and approved by the Engineer. Conceptual arrangement of civil works supported by calculations shall be submitted along with tender bids. Later on, detailed construction drawings and design calculations for all civil works for static as well as dynamic analysis (wherever essential) shall be submitted for approval prior to undertaking construction work. Design calculations shall be done in STRAPP / M.S. Office (latest version) and Drawings shall
Technical Specification:Sec-7, Civil
Page 1 of 21
3.4
3.5
3.6
3.7
4.0
be prepared in Auto Cad (latest version). The analysis analysis shall be done by using STADD PRO / ANSYS / STRAPP (latest version). However design may be carried out by manually, using computer worksheets or by using suitable software programmes, as mutually agreed by Employer/RITES. Final calculations and drawings drawings shall be submitted in Compact Disc (CD) (2 Sets Civil Task drawings indicating various equipment loading and supporting arrangement and floor loads shall be submitted along with design calculations. Soft copies of all STAAD input files shall be submitted along with the design calculations for all revisions Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works shall be submitted structure wise and area wise for Employer’s record. However each drawing shall indicate te approximate quantity of structure (Sectionwise) Concrete (Grade wise) and reinforcement Diameterwise.) Structural steel fabrication drawings to be prepared by the contractor will not be approved by the Employer/RITES. However, the Contractor for Employer’s Employer’s reference shall submit all fabrication drawings. Copy of detailed bar bending schedule as prepared by contractor shall also be submitted to the Engineering and also to Engineer in charge for the reference Approval of construction drawings prepared prepared by the contractor shall not relieve the Contractor of his responsibility regarding the adequacy of design and correctness of the drawing.
WORK DESCRIPTION. It includes the Civil, Structural and Architectural works related mainly to the following areas (but not limited to): 4.1 Wagon Tippler Hopper, Machinery Hatches and Underground Tunnel Wagon Tippler hopper and machinery hatches shall consist of underground portion, which shall be of R. C. C., and above ground portion, which shall be of structural steel shed covered with Aluminium Industrial troughed sheets. It essentially consists of R. C. C. frames with R. C. C. wall panels on the sides and R. C. C. raft at the bottom, fixed to the frames. The top beam of the R. C. C. frame supports the rail supporting beams and the hopper. Minimum thickness of R. C. C. raft at bottom shall be 600 mm. Minimum thickness of RCC side walls shall be 600 mm at bottom and 300 mm at top. No columns shall be provided inside the Machinery Hatches. The vertical and inclined portion of coal hopper shall be provided with 50 mm thick guniting (shotcreting). Details of shotcreting have been given elsewhere in this specification Expansion joints shall be provided at a maximum distance of 40m unless otherwise otherw instructed. 600 mm wide water stop fabricated with 22G copper plate with bitumen board fillers and polysulphide sealing compound as specified elsewhere shall be used as expansion joint material. Floor shall be provided with cross slope not flatter than 1 in 50 towards side drains. Side drains shall be sloped towards sump where sump pumps as specified elsewhere, shall be provided. The slope of side drains shall not be flatter than 1 in 400. Arrangement shall be made for disposal of water right up to the discharge point. Side drains and sump shall have removable type steel grating cover. Gratings shall be galvanized to grade 610 gm/m.2 Water proofing / Damp proofing of under ground portion of hopper and machinery hatches, tunnels, underground (i. e. basement) basement) portion of transfer houses shall be done by providing the following treatments: Chemical injection grouting for inner faces (details as specified elsewhere). Polymer modified cementitious coating on earth side face as per the following : ter surface of walls, frames and roof slabs coming in contact with earth, 1). On the outer polymer modified cementitious coating in two layers as specified and as per manufacturer’s specifications shall be provided directly on the concrete surface. (2.) 50 mm thick P. C. C. (1 : 2 : 4 with 10 mm nominal size stone aggregates) shall be provided under the raft i.e. over the lean concrete, followed by polymer modified
Technical Specification:Sec-7, Civil
Page 2 of 21
cementitious coating in two layers ( slurry mix application ) as per manufacturer’s specification. 50 mm thick ck P. C. C. ( 1 2 : 4 ) with 10 mm nominal size stone aggregates shall then be laid over the polymer modified cementitious coating before laying the raft. Hopper shall have removable type steel grating cover. The opening size for the grating shall be 300 mm x 300 mm. Machinery hatches shall have removable steel chequered plate cover. Hopper grating shall be built of min. 200mm x 36mm thick flats. No painting/galvanization shall be provided in gratings. However, two coats of red oxide primer to be provided immediately after fabrication. Catwalk shall be provided along the hopper. Each machinery hatch shall be provided with a pair of R. C. C. stair for providing access to the base of track hopper / machinery hatch. Both the stairs shall be interconnected at suitable s height. Plinth protection along with drains shall be provided along the Hopper and around machinery hatches. However, paving shall also be provided around machinery hatches. The wagon tippler hopper is a deep underground structure which is subjected subjecte to direct load from the loaded wagons / loco due to the rake movement over it, in addition to load due to coal filled hopper and lateral earth pressure. The railway loads, analysis and design of hopper, machinery hatches, transfer point and the portion of of tunnel subjected to rail loads shall be as specified in design criteria. Coefficient of dynamic augmentation shall be worked out for a train speed of 30 kms per hour. Earth pressure to be considered for design shall be due to earth pressure at rest (K 0)condition condition only. Earth pressure due to surcharge intensity of Railway Loads (where applicable) or Uniformly Distributed Load (U. D. L) of intensity 2 T / Sq. M. whichever is critical, shall be considered in the design. A minimum safety factor of 1.2 against uplift of hopper, machinery hatches, wagon tippler, transfer points (underground or with basement) and tunnels, due to ground water shall be ensured during execution and after execution, considering dead weight of the structure to be 0.9 times only, ground ground water table at adjoining formation level and soil wedge angle of not more than 15 degrees. Also, FOS against uplift, to be taken as 1.0, considering the dead wt. of structure and soil resting on side projections if any in the vertical plane. Inclined wedge wedge action of soil shall not be considered in this case. Walkway width and hand railing shall be provided as specified in the tender drawing. Wherever, slope of tunnel exceeds 10 o, R. C. C. steps shall be provided for the entire width of each walkway. n Tippler hopper structure shall be analyzed and designed for the worst load Wagon combinations.
4.2
Overhead / Ground Conveyor Galleries and Trestles
Overhead conveyors shall be located in a suitably enclosed gallery of structural steel. The overhead gallery shall consist of two vertical latticed girders having rigid jointed portal frame at both ends. Cross beams at floor level supporting conveyor stringer beams shall be made of single rolled steel beam or single channel section (ISMB or ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of the gallery (latticed girders shall be braced together in plan at the top and bottom).Common end portal frame shall not be used for adjacent conveyor spans. Roof trussshall be provided at upper upp node points of latticed girders to form an enclosure. Themaximum span of overhead gallery shall be limited to 25 meters unless higher spanis required due to site conditions, which shall be subject to approval of the Engineer.The gallery should as far as possible be erected as a box section keeping all thevertical and horizontal bracing tied in proper position. The gallery should be checkedfor all erection stresses that are likely to develop during handling and erection and ifrequired, temporary strengthening strengthening of gallery members during erection shall be made.Seal Technical Specification:Sec-7, Civil
Page 3 of 21
plates under the conveyor galleries shall be provided in such a way thatcomplete gallery bottom shall form a leak proof floor. The ground conveyors shall be located in suitably enclosed gallery of structural steel consisting of rigid portal frames spaced at regular intervals and suitably braced. Plinth protection along with drains shall be routed along the ground conveyors. Hand railing r should not be supported on conveyor supporting stringers. The walkways shall be chequered plate construction with anti - skid arrangement. Conveyor gallery shall have Aluminum industrial troughed sheets conforming to IS:1254 on roof & both sides. Adequate provision of windows shall be kept on both sides of conveyor gallery as appended in Mechanical Section. Windows shall be provided with wire mesh as specified elsewhere in this specification. Cross - over with chequered plate platform and ladder for crossing over the conveyors shall be provided at approximately every 100 M intervals of conveyor. Crossover shall preferably be located over four-legged four rigid trestle location. For railway tracks passing below overhead conveyor gallery and along conveyors, the railway clearances both underground as well as over ground shall have to be adhered to for design, execution and erection of foundations, trestles, galleries etc., so that movement of locomotives and wagons is not hampered in any way during during execution and afterwards. However at the location where the overhead conveyor gallery crosses road, minimum clearance of 8.0m above the road crest shall be provided. a) All gallery supporting trestles shall be four legged type only. One end of each gallery span shall be hinged to the supporting trestle and the other end shall be slide type. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements. a) In between transfer houses / buildings, four legged trestles trestles shall be placed at a maximum interval of 90 metres. The arrangement shall be such so as to ensure that force in the longitudinal direction (i. e. along the conveyor length) of conveyor gallery of length not more than 90 m is transferred to any four legged legged trestle. In the space between each successive four legged trestles, two legged trestles shall be provided at regular intervals. The end supports resting on the four-legged four legged trestle can have either ends hinged or one hinge and the other on slide type depending depending on the arrangements. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements. End of conveyor gallery which will be supported over transfer house, shall be so detailed that only vertical reaction is transferred ferred from conveyor gallery and no horizontal force in longitudinal direction is transferred from conveyor gallery to transfer house structure and vice - versa. For trestles and trestle foundations for conveyor galleries located adjacent to existing structures, struc over ground and under ground facilities, location and details of these trestles and foundations shall have to be decided such that there is no interference both underground as well as over ground with existing structures and facilities. Trestle columns columns / ground conveyor portal column base shall be kept 300 mm higher than the existing ground level.
4.3
Transfer Houses
The over ground portion of the transfer house shall be framed structure of structural steel work with Aluminium Industrial troughed sheet sheet side cladding and R. C. C. floors and roof over structural beams. However the lower portion of side cladding for a minimum height of 0.9 m above the finished floor level shall be one brick thick wall plastered on both side. In some areas like MCC floors etc., one brick thick wall cladding shall be provided. Brick wall cladding shall be supported on encased wall beams and suitably anchored to adjoining columns and beams. Roof shall be provided with water proofing treatment as specified elsewhere. Adequate steel doors and windows for proper natural lighting and ventilation Technical Specification:Sec-7, Civil
Page 4 of 21
shall be provided. In addition to steel windows, panels of suitable size to suit the architectural treatment and made of translucent sheets of polycarbonate material shall also be provided d on the side cladding for natural lighting.
4.4
Control building, M. C. C. Buildings
These shall be R. C. C. framed structures with columns, beams, slabs and foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof shall be provided pro with roof water proofing treatment, as specified elsewhere in the Technical specification. In case of control building suitable permanent interconnection shall be provided at appropriate level with the existing respective buildings. All air - conditioned oned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system (details specified elsewhere). Adequate aluminium doors and windows shall be provided for natural lighting, ventilation and view.
4.5
Pump Houses
Thesee shall be of R.C.C. or steel framed structure with columns, beams, slab andfoundations etc. cladding shall be of brick work with plastering on both sides. Roofshall be provided with roof water proofing treatment as specified elsewhere.Underground sump and water tanks shall be of R.C.C. Adequate number of doors,Windows and Rolling Shutters shall be provided.Galvanized steel ladder / rung ladder shall be provided for access to the roof level ofthe pump house and water tanks. 4.6 Pent House These shall be of R. C. C. framed structures with columns, beams, slabs andfoundations etc. Cladding shall be of brickwork with plastering on both sides. Roofshall be provided with roof water proofing treatment as specified elsewhere. Adequate nos. of steel doors and windows window shall be provided for natural lighting and ventilation. 4.7 Toilets Toilet with potable water line facilities shall be provided in each of the following locations: In all M. C. C. Rooms Control Building Each unit shall have brick enclosure, and the following fittings. i ) Squatting type, white, vitreous china Orissa 1 No. pattern, W.C. pan with high level flushing cistern ( C.I. ) and all requisite fittings ii ) Bowl type Urinal with automatic flushing 2 Nos. cistern ( C.I. ) and all requisite fittings iii ) Wash Basin 630 mm x 450 mm with 2 Nos.two taps and all requisite items iv ) Mirror 600 mm x 450 mm x 5.5 mm thick 2 Nos.with bevelled edges ( Superior sheet glass ) v ) C.P. Brass Towel Rod 600 x 20 mm 1 No. vi ) Liquid Soap Container 2 Nos. vii ) Washing Tap ( CP Brass ) 2 Nos. viii ) Overhead Polyethylene water tank 1 No.(min. 500 litres capacity) ix ) Suitable provision for installation of water coolers.
4.8
Staircase
All roofs & floors of transfer houses shall be accessible through staircase. However,for the pump houses, access to the roof will be provided by cage ladder. All stairs other than those of M. C. C. rooms and control rooms shall be of steel (minimum (minimum 1000 mm wide)and maximum rise should not be more than 180 mm and minimum tread width 250 mm. Stringers shall be of rolled steel channel( minimum ISMC 250 )and tread shall be of steel gratings. Stairs shall be provided with 32 mm dia nominal bore medium medium duty M. S. pipe hand rail. Handrails (for staircases, around openings, in walkways etc.) shall be of standard weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal bore medium class pipe provided with double rail, top rail about about 1.0 metre above platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail post may be provided when Technical Specification:Sec-7, Civil
Page 5 of 21
specifically called for in drawings approved by Engineering. Handrails around openings should have toe plates. Smooth uniform curves and bends shall be provided at stair returns and also where so ever required. Posts connected to curb plates shall have a neat closure at the bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All necessary fittings including ncluding inner dowels at splices, brackets, belts, bends, flanges and chains, where required shall be plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all points of direction changes in the handrail. Treads and landing shall be suitable for the prescribed loading. The maximum width of openings in gratings shall not exceed 40 mm. The minimum thickness of main bars shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. Stair case gratings shall be galvanized to grade 610g/m2 Out side stairs to transfer points shall be open type. However RCC slab shall be provided at the top. Stairs of control room and M. C. C. room shall be of R. C. C. construction, and minimum 1200 mm wide, maximum rise should not be more than 180 mm and minimum tread with 250 mm. Numbers and arrangement (including enclosures etc.) of stair cases shall be such as to meet the fire safety requirement as per guide lines of statutory regulatory bodies. 4.9 Trenches All trenches for cables or any other underground facility as detailed out elsewhereshall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers /chequered plate cover. Cable trenches as well as pre - cast covers shall be providedwith edge protection protectio angles and lifting hooks. All embedments / block outs asrequired and specified elsewhere in these specifications shall be provided. Properdrainage arrangement shall be provided. Trench pre - cast cover weight shall not bemore than 65 Kgs. Trench covers near n entry or at road crossings shall be designedfor 10 T wheel load at centre. Pre - cast covers shall be designed for central pointload of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection ofcables, up to top level and covered with pre - cast R. C. C. covers. For cabletrenches outside buildings, top level shall be 200 mm above G. L.Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protectionall around cut outs / openings in floor slabs, edges of drains supporting grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers, supported edges of pre - cast cover, treads of RCC stairs. 4.10 Approach Road All approach road required within battery limit is under the scope of the agency with its connection ion to main road. All approach roads shall be constructed with RCC over suitable hard sub base.
5.0 5.1
Drainage & Water Supply Works Drainage System:System:
The drainage arrangements shall be so planned so as to ensure quick disposal of drainage water without stagnation tagnation and / or overflow. The water shall overflow into contractor’s R.C.C drain, which will lead the discharge finally into owner’s drain. Contractor’s scope shall also include construction of necessary culverts under the rail lines / roads as per railway rai / I. R. C. standards and approval of Railway culverts from concern Railway authorities 5..2 Internal and external water supply, drainage etc.:etc.: The scope for potable water supply includes all distribution systems, tanks, pipes, fittings etc. as required ed and as described here or elsewhere in these specifications. The scope for service water supply and dust control water supply shall be as described elsewhere in these specifications. For water supply, medium class galvanized mild steel pipes conforming to IS: 1239 shall be used. The scope for drainage of surface water shall include design, layout and construction of drains for and from buildings and drains required for wagon tippler area. All buildings (including transfer houses and crusher house) shall be provided with open surface Technical Specification:Sec-7, Civil
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drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All drains shall be of R. C. C. construction. All open drains shall have removable steel grating designed for loads as specified under loading clause. clause. Minimum thickness of grating (Galvanised to 610 gm/m) 2 shall be 12 mm. However at entry or road crossing point’s minimum thickness shall be 40 mm. The opening size of grating shall not be more than 90 mm x 35 mm. All drains as well as pre - cast covers vers shall be provided with edge protection angles and lifting hooks. However, drains in coal stockyard area shall have pre cast R. C. C. covers. RCC pre - cast cover weight shall not be more than 65 Kgs. RCC pre-cast pre covers near entry or at road crossings shall be designed for 10 T wheel load at centre. RCC pre – cast covers shall be designed for central point load of 75 Kgs. The scope for foul water from toilets shall include layout and laying of sewers up to the Employer’s main sewer line for sewerage system stem together with all fittings and fixtures and inclusive of ancillary works such as connections, manholes and inspection chambers within the building and from the building to the Employer’s sewer line. For rain water down comer and those to be used for conveying onveying water / coal slurry generated from cleaning of conveyor gallery and buildings floors, Galvanised MS pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded joints shall be used for MCC buildings, pump houses, penthouse, control contro rooms. Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330 conforming to IS: 3589 with welded joints shall be used for all TP’s, and Conveyor galleries. Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall be subjected to testing as per IS: 2633, for uniformity of coating. The zinc coating shall be free from all defects as per IS: 2629. All rain water down comers shall be provided provided with roof drain heads and complete with shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive painting over a coat or primer. For design of building drainage system IS: 1742 shall be followed. For sanitary / sewerage pipes pipes above ground, sand cast iron pipes conforming to IS : 1729 with leak proof lead joints. For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail crossing sing R.C.C. box culvert to be provided. For sewerage below ground stoneware pipes conforming to IS: 651 with concrete bedding and haunch.
6.0
COLOUR COATED AND OTHER SHEETING WORK
Permanently colour coated sheet of approved shade and colour using galvanized galvanize mild steel sheet of minimum 0.6mm BMT(bare metal thickness i.e. metal thickness excluding thickness for coating and galvanizing) galvanised to grade 275 as per IS 277,of minimum yield strength of 250 Mpa of drawing grade as per IS 513 or high tensile steel steel of minimum 0.5mm BMT(bare metal thickness i.e. metal thickness excluding thickness for zinc aluminium coating and colour coating ) coated with zinc aluminium alloy @ 150gm/sq.m.of minimum yield strengthof 350 as per AS1397. Steel shall be colour coated coated with total coating thickness of 35 microns (nominal) comprising of silicon modified polyester (SMP with silicon content of 30% to 50%) paint or Super Polyester paint, of minimum 20 microns (nominal) dry film thickness (DFT) on external face on 5 microns (nominal) primer coat and 5 microns (nominal) SMP or super polyester paint over 5 microns (nominal) primer coat (or 10 micron SMP/super polyester paint) on internal face. SMP and Super polyester paint systems shall be of category 3 as per AS2728. Coated surface surface shall be provided with a protected guard film (polyethylene) of about 40 microns to avoid any damage to the coating during handling. For metal deck, minimum 0.8 mm (bare metal thickness i.e. metal thickness excluding thickness for coating and galvanizing) izing) galvanised to grade 275 as per as per IS 277, of minimum yield strength of 250 Mpa of drawing grade as per IS 513, troughed profile having nominal trough depth 44 mm and pitching of 130 mm shall be used. However alternative profile meeting the strength, stren defection and other functional requirements such as sections modulers and moment of inertia shall be provided. To minimize the number of joints, the length of the sheet shall Technical Specification:Sec-7, Civil
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preferably be not less than 4.5 cut pieces shall not be used, unless specifically specifi approved by the Engineer. However, the actual length shall be such so as to suit the purling / runner spacing. No negative tolerance shall be allowed in bare metal thickness. The nominal depth of trough shall be 30 mm. The polycarbonate sheet to be used used for cladding and glazing purpose in conveyor galleries shall have toughed profile to match with the metal cladding profile. Minimum 2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic or equivalent approved make shall be used. The polycarbonate sheet shall be installed along with the metal cladding so as to have a watertight lapping arrangement. Suitable detailing shall be made to cater for the thermal expansion. IS: 14434 to be referred for other details. Polycarbonate sheet sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous use under temperature 100 oC), impact resistant and ultraviolet resistant sheet shall be provided (as glazing) in transfer houses, pump houses, etc.
7.0
Roof Details
Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom. For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This gradient can be provided ided either in structure or subsequently by screed concrete M-15 M (using 12.5 mm coarse aggregate) and / or cement mortar (1:4). However, minimum 25 mm thick cement mortar (1: 4) shall be provided on top to achieve smooth surface.900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided over roofs of all buildings. Parapet wall shall have suitable coping. External face of parapet wall of the buildings provided with metal cladding shall also be finished with metal cladding of design and colour col as per approved architectural drawings. Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet. Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness of 30 mm of M-15 15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished with 12 mm 1 : 3 cement : sand plaster. Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms, penthouse etc., shall have roof water proofing treatment. Roof water proofing treatment shall be provided ided using high solid content liquid applied urethane based elastomeric water proofing membrane to give uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898), with separate wearing course as per ASTM C - 898. This treatment shall also include application of polymerized mastic over the roof to achieve smooth surface and primer coat. Wearing course on the top of membrane shall consist of 25 mm thick P. C. C. (M-15) (M cast in panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized chickenwire mesh and sealing of joints using sealing compound / elastomeric water proofing membrane. Pathways for handling of materials and movement of personnel shall be provided with 22 mm thick chequered cement concrete tiles as per IS : 13801 for awidth of 1000 mm in place of P. C. C.
8.0
Floors and Grade level details
The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom Floors of transfer points shall have cross slope of not flatter than 1: 80, towards the floor washing drainage outlets, for efficient drainage. For ground conveyor & crusher house slope shall be 1:100. Chequered plates (used for floors, walkways etc.) shall be minimum minimum 6 mm thick o/p or as indicated on drawings. The chequered plate pattern shall be approved by Employer / RITES. Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered plates at a designed spacing to stiffen chequered chequered plates suitably. Chequered plates shall be fixed by staggered welding of suitable size. Floors of trenches shall have integral finish to concrete base. Toe guard of size 100 x 6 mm shall be provided at various openings provided in floors e.g. around stair stair case openings, chute openings and other similar cutouts. For conveyor walkways, angle runner to act as toe guard shall be provided. All along the Technical Specification:Sec-7, Civil
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periphery of R. C. C. floors (where no brick masonry walls are provided)shall be provided with one brick thick hick 300 mm high brick wall and 700 mm high steel hand rails all around over this brick work. All buildings (including track hopper and machinery hatches, penthouse, transfer houses ) and ground conveyors shall be provided with 750 mm wide plinth protection n all around. It consists of 50 mm thick P.C.C. M-20 M 20 grade with 12 mm maximum size aggregate over 200 mm thick stone soling using 40 mm nominal size rammed, consolidated and grouted with fine sand. An area of 5 m width all round the transfer houses shall bee paved. This paving will be in addition to plinth protection. Plinth level of all buildings shall be kept at least 500 mm above the finished grade / formation level. 9.0 Brickwork and allied masonry works All brick walls shall be non - load bearing in-filled filled panel walls. All brickwork shall be designed as per Indian Standards and shall be plastered on both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand mortar. Brick walls shall shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand plaster on smooth and rough face of the brick work respectively. Bricks to be used in brickwork shall be of minimum Class designation 50. Brickwork cladding for various structures shall be so provided provided that there is a clear gap of 40 mm between inside face of external brick wall and outside face of column flange. Structural steel wall beams supporting brickwork shall be suitably encased with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam, encasement shall be done with cement sand plaster in specified thickness and proportions over G. I. wire netting of 0.9 mm thickness. Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be provided with drip course in 1 : 4 cement sand mortar.50 mm thick Damp proof course shall be provided at plinth level for all brick wall. All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided with false ceiling) shall be provided with 6 mm thick plaster.
10.0
Earthing Mat
2X40 mm Dia MS rod as earthing mat, placed at a distance of 1.0M away and at depths between 0.60M and 1.00M shall be supplied and laid all around around the periphery of buildings, structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS rod and connecting to the above Earthing mat shall also be supplied and laid in position by the Contractor, as per the approved drawings. drawings. Risers shall be laid up to a height of 300 mm above the local Ground level, at each of the columns of the buildings on outside of the buildings, and minimum 2 (Two) numbers for structures and outdoor equipment. The contractor also supply and lay necessary necessary number of 3.0 M deep vertical 40 mm Dia MS rod Earthing electrodes and connecting them to the Earthing mat, as per the approved drawings and the supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing mat with the Employer's r's earthing mat separately at two locations.
11.0
Fencing
Fencing with toe wall and steel gates shall be provided around the transformers. Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G (including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall. The diameter of the steel wire for chain link fence (excluding PVC coating) shall not be less than 12G. Fence posts shall be of pre – cast R. C. C. of minimum M20 grade. All corner posts will have two stay posts and every tenth post will have transverse stay post. Suitable R. C. C. foundation for the post and stays shall be provided based on prevailing soil conditions. Gates shall be sturdy with locking provisions. Toe walls of brick masonry shall be provided between fence posts all along the run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend minimum 300 mm below the formation level. Toe wall shall be plastered plastered on both sides and painted with two coats of cement paint of approved colour and shade. Toe wall shall be provided with weep holes at suitable spacing. Technical Specification:Sec-7, Civil
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12.0
LOADING
For consideration of loads on structures IS : 875 - ‘Code of practice for structural safety sa of buildings’ shall be followed. In addition to the dead load, live load, equipment load (including impact / vibration). Temperature loads etc. various loading conditions arising due to operation and maintenance of equipment shall be considered in the design. The structure and equipment shall also be designed for seismic loads as per the “Criteria for Earthquake Resistant Design of Structures and equipment" and the “Criteria for Wind Resistant Design of Structures and equipment" specified in the Annexure Annexure A and B respectively in Civil Section, whichever is governing. Wind and seismic forces shall not be considered to act simultaneously. The following minimum live loads shall be adopted for the design of various structures. If actual expected load is more than the specified load, then actual load is to be considered a )Roofs 150 Kgs. / Sq. M. for accessible roofs and 75 Kgs. / Sq. M. for non accessible roofs. In addition to this coal dust load of 150 Kgs. Kgs. / sq. m. shall also be considered. b ) R. C. C. floors 500 Kgs. / Sq. M. c ) Stair and balconies 500 Kgs. / Sq. M. d ) Toilet rooms 200 Kgs. / Sq. M. e )Chequered plate floors 400 Kgs. / Sq. M. f ) Walkways ( including walkways in 300 Kgs. / Sq. Sq. M.conveyor galleries ) g)Conveyor galleries In addition to the live loads, loads due to cable trays, fire fighting / service water pipes shall also be considered @ 125 Kgs. / m ( minimum ) on each of the longitudinal girder. Roof-truss Roof members are to o be checked for supporting fire fighting pipes/Service water pipes. h ) Road Culverts and its allied For class 'AA' loading and checked for structures including R. C. C. pipe class A loading as per IRC standard crossing & road crossing of trenches. i ) Channels / trenches In addition to earth pressure and water pressure, etc. additional earth pressure due to surcharge of 2T / Sq. M. shall j ) Covers for trenches/channels Covers for channels & trenches, shall be designed for a live load of 0.4T Sq.M. M. &loading mentioned under clause in trenches, whichever is critical. k ) Sumps and tanks and other In addition to earth pressure with a underground basement type surcharge of 2T / Sq. M. (or surcharge structures due to Railway loading whichever is critical for Railway load bearing structures etc.) and sub - soil water pressure etc. These are also to be designed for the following conditions : i ) Water / liquid inside and no earth outside (applicable only to such structures which are liable to be filled up with water or any liquid ). ii ) Earth with surcharge outside and no water / liquid inside iii ) For underground (basement) structures protection against buoyancy during execution and after execution shall be ensured without superimposed loadings with minimum factor of safety of 1.2 against buoyancy. l ) Unit weight of coal shallbe taken as 1100 Kgs. / cum. Fordesign purposesIf the erection er load is higher than the specified live loads on any floor or part thereof,then the erection loads are to be considered for the design.Permissible increase in stresses of materials and bearing pressure of soil due to windload or seismic load shall be as per relevant I. R. S. and I. S. code.
13.0
DESIGN CRITERIA
The loads for all railway load bearing structures e. g. track hopper includingmachinery hatches, wagon tippler, tunnel and under ground transfer houses etc. and the analysis and the design of these structures shall be made strictly in accordancewith the provisions pr of Indian Railway Bridge rules (latest edition), and Indian RailwayCodes of practice (latest Technical Specification:Sec-7, Civil
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edition) with all amendments up to the date of opening ofbids. However, the axle load for analysis and design shall be considered as 35 MT.Coal heap of 1.2m 1.2m height shall be considered above hopper top for design of, hopper and supporting elements of hopper. The analysis, design anddetail drawing for the structure coming below the railway track shall be got approvedby the contractor from the concerned railway railway authorities before taking upconstruction. All necessary payment for the above work shall be made by the bidder to the railway authority.The design of all R. C. C. structures shall be carried out as per ‘code of practice forplain and reinforced concrete for general building construction’, IS : 456 ( latest ). The steel structures shall be designed and fabricated as per ‘code of practice for use of structural steel in general building construction’, IS : 800 ( latest ) and other relevant IS Standards. Minimum mum size of the angle section to be used as structural members shall be 50X50X6. Minimum weld size shall be 6 mm. Connections shall bedesigned for 70% of shear capacity of the member or the actual shear force, whichever is higher. The building shall conform to local bye - laws, rules and regulations for industrial buildings and also B. I. S. publications, SP 32 and 41. Slotted holes shall not be assumed to act as expansion joint for relieving of stresses and suitable bearings shall be provided at the supports. supp All gallery supporting trestles shall be so proportioned that the transverse deflection of gallery due to wind / seismic load should not exceed trestle height / 1000 as stipulated in IS: 11592. This deflection condition shall be strictly followed. The The transfer house structures shall be so designed that transverse deflection at places where conveyor galleries meet, should be equal to the respective transverse deflection of conveyor supporting trestles. Horizontal bracing system shall be provided at floor floor levels around the openings. Shear force in steel columns shall be transferred to the pedestals / foundations exclusively either through foundation bolts or the shear key arrangement. For design of liquid retaining structures, IS : 3370 ( Part - I to IV ) ( latest ) shall be followed. Face of the structure in contact with liquid shall be designed as un -cracked cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458, IS : 783 should be followed. For design of all underground structures struct / foundations, ground water table shall be assumed at the formation level ( i. e. the adjoining ground level ). Design of Hopper walls shall be done for both Static & Dynamic flow condition using Walker’s theory. Design of masonry walls shall be made as per IS : 1905. Civil task drawing indicating various equipment loading and supporting arrangement and floor loads to be submitted along with the design calculation. For metal roofing and side cladding, the spacing of purlins/runners shall be such that the the deflection of metal sheet used is limited to span/250 under adverse loading condition. Minimum reinforcement shall be provided at the top face of the footing, even if, no reinforcements are required as per design
14.0
CONCRETE
All R. C. C. works to the done under this specification, unless specified otherwise shall be design mix concrete. Minimum grade of concrete for various structures shall be as follows: a ) M35 - For all railway load bearing structures b ) M25 - For underground / sub structural R. C. C. work (other than railway load bearing structures). C ) M20 - For R. C. C. superstructure works including ground floor slabs, trenches & drains. Minimum 75 mm thick P.C.C M-7.5 M 7.5 shall be provided as mud mat below all foundations. For concreting of underground structures requiring water tightness, plasticizer cum water proofing admixture shall be added to the concrete mix. Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting etc. unless otherwise directed. Batching plant or reversible drum mixer with weigh batcher and concrete pumps must be used for all concreting works(RCC).
15.0 15.1
Excavation Details Excavation in soil
Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing Technical Specification:Sec-7, Civil
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or as directed by the Engineer. The bottom of all excavations shall be trimmed to required levels and when excavation is carried below such levels by error, it shall be brought back to the specified level by filling with concrete of nominal mix 1 : 3 : 6 (cement: (cement: coarse sand: 40 mm down aggregates ), as directed by the Engineer. The Contractor shall ascertain for himself the nature of materials to be excavated and the difficulties, if any, likely to be encountered in executing this work. Cofferdams, sheet piling, piling, shoring, bracing to maintain suitable slopes, draining etc. shall be provided and installed by the contractor, to the satisfaction of the Engineer. Surplus excavated materials shall be disposed off by the contractor at locations within plant boundary wall as directed by the engineer. The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, Backfilling is completed. The Contractor shall remove all slush/muck from the excavated areas to keep the work area dry. The Contractor, if required, shall employ sludge pumps, for this purpose.
15.2
Excavation avation in rock
For the work of excavation in rock, Contractor shall engage specialized agency having experience of excavation in rock involving wedging and blasting. The agency shall be subject to approval of Engineer and the Contractor shall furnish details details of relevant experience in support while seeking approval for the agency. agency Only Control Blasting shall be resorted resort to with the written permission of the Engineer. In case blasting method can not be adopted considering the safety aspect of the existing rail rail network, buildings, structures etc, hard rock shall be excavated by using expansive chemical or any other suitable means. means All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to the acquisition, transport, storage, handling and use of explosives etc. shall be strictly followed. The contractor shall obtain Licenses from Competent Authorities for undertaking blasting work as well as for procuring, transporting to site and storing the explosives as per Explosives es Act. The Contractor shall be responsible for the safe transport, use, custody and proper accounting of the explosive materials. Surplus excavated materials shall be disposed off by the contractor at locations within plant boundary wall as directed by the th engineer. The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, shuttering, concreting, backfilling is completed.
15.3
De-watering watering of Deep Excavations
For deep underground structures like wagon tippler hopper, machinery hatches, tunnels and underground transfer houses, requiring open excavation with extensive de - watering, completely letely dry working conditions during excavation, shuttering, placement of reinforcement, concreting, water proofing of structures, backfilling and any other operation shall be maintained by suitable de - watering method of suitable capacity.
15.4
Backfilling, ng, Disposal and Stacking of materials
Backfilled earth shall be compacted to minimum 90 % of the standard proctor density at OMC. Sand filling shall be compacted to minimum 80 % of the relative density. However, the backfill under the rail lines and roads shall be compacted to minimum 95 % of the standard proctor density at OMC unless otherwise stated by rail Authorities. The contractor is required to excavate upto any depth as shown on the drawings or as directed by the Engineer. Lifting of excavated materials materials shall be done either by manual or mechanical or both means if called for by the Engineer. The disposal / stacking areas for excavated materials shall be indicated by the Engineer. If directed by the Engineer this material shall be used directly for filling illing purposes. For leads exceeding 500 m the Contractor shall transport the excavated materials by mechanical means only and as directed by the Engineer. The Contractor may be allowed to carry materials through Kuccha roads. Providing and Technical Specification:Sec-7, Civil
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maintaining of the Kuccha roads shall be the responsibility of the Contractor. The transported material shall be neatly stacked as directed by the Engineer. Double handling of materials shall be avoided as far as possible. However, depending on site condition excavated materials carried beyond a lead of 500 m may also be required to be brought back for filling purpose. Materials to be used for filling purpose shall be stone, sand or other inorganic materials and they shall be clean and free from shingle, salts, organic matter, m large roots and excessive amount of sod, lumps, concrete or any other foreign substances which could harm or impair the strength of the substances in any manner. All clods shall be suitably broken to small pieces. When the materials are mostly rock boulders, these shall be broken into pieces not larger then 150 mm size. Sand used for filling shall be clean, medium grained and free from impurities. Fines less than 75 microns shall not be more than 20%. In any case, the materials to be used for filling purposes shall have the prior written approval of the Engineer. In case the materials have to be brought from pits / quarries, then it shall be the Contractor’s responsibility for identification ion of such quarry areas, obtaining approval from their use from concerned authorities, excavation / quarrying loading and carriage of such material, unloading and filling at specified locations. The Contractor shall pay any fees, royalties etc. that may have to be pain for utilizationof borrow areas.
16. 0
GALVANISING SING
All burrs and irregular edges of the structural steel members to be galvanized shallbe ground smooth before galvanizing.Purity of Zinc to be used for galvanizing shall be 99.5 % as per IS : 209 ( latestedition ).The weight of the zinc coating shall be at least 610 Gms. /m2unless noted otherwise.
17.0
CHEMICAL INJECTION GROUTING
Minimum, 12 mm dia ( NB ) threaded nozzle of suitable length, shall be provided over the surface and along the construction joint line in a grid pattern at a spacing not exceeding excee 1.5 m c / c before concreting operation. Adequate precaution shall betaken to keep the nozzles plugged at both ends to prevent them from getting closedby concrete. For fixing of any nozzle in set concrete suitable size hole shall be drilled, preferably preferably by using repercussive hammer drill electrically operated, in grid pattern and grouting nozzle shall be fixed in these holes. After the nozzles are fully set, neat cement slurry admixed with water soluble non shrink polymer / monomer based chemical shall shall be injected through the net - work of nozzles with low pressure grout pumps at a pressure of about 2.0Kgs. /cm2. Cement slurry shall be prepared by mixing cement with non-shrink non shrink polymer/monomer @ 500 gm/50 kg bag of cement and water, ensuring that Water: Cement ratio does not exceed 2 (by weight). Wetter the structure, lesser should be the water cement ratio. The property of the polymer/monomer should be such that when it is mixed with water @0.5% by weight of water, the viscosity of the resultant solution solution (water and polymer/monomer) should not be more than 1.2 centipoises. Plasticizing agent shall be added wherever required. The grouting shall be started at very low pressure and increased gradually to a required pressure. The grouting shall continue, till till the hole refuses to take any further grout, even at an increased pressure. Applied pressure shall not be more than the designed strength of the concrete. After completion of grouting operation, the nozzles shall be sealed properly to the satisfaction of the Engineer.
18.00 POLYMER MODIFIED CEMENTITIOUS COATING 18.1 Materials Modified liquid polymer blend shall be a dispersion containing 100 % acrylic based polymer solids. Polymer shall be mixed in the ratio of 1 cement: 0.5 polymer (for minimum solid content of polymer 30%). Portland cement based dry powder. Clean, fine specially prepared quartz sand approximately 0.6 mm size.
18.2
Mixing
The liquid polymer shall be stirred well and cement based powder shall then be added Technical Specification:Sec-7, Civil
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slowly to make a Slurry Mix. For preparation of Brush Topping Mix, quartz sand shall be added slowly and mixed well till a homogeneous mixture is obtained. The mix shall be used within half an hour of the preparation. Addition of quartz sand may not be necessary, in case dry power contains the same.
18.3
Properties of Coating
It must adhere to wet surface. It should develop adequate bond strength, with the concrete surface, not less than 2N / Sq. mm.Co - efficient of permeability shall be about 5x10Cm / Sec.-1 0 Waterr absorption after continuous soaking shall not be more than 1 %. The materials shall be permeable under water vapor. The material shall be resistant to acids and alkalis present in the soil and underground water with normal pH value between 4 and 14. The co - efficient of thermal expansion of the material shall be close to that of concrete
18.4
Application
The concrete surface shall be cleaned and made free from grease, oils or loosely adhered particles. The surface shall be damp without any free water. For For exterior underground part, application (b) pertaining to Brush topping Mix shall be followed.
(a) For Slurry Mix A minimum of 2 coats shall be applied on the surface. The first coat being applied, when the surface is still damp and left to harden for 4 to 6 hours. After 4 to 6 hours of the application of second coat, it shall be finished by rubbing down with a soft dry sponge. The coverage shall not be less than 1 : 1 Kgs. / m in the 2 coats. A lap of 75 2 mm shall be provided at the joints. The coating shall shall be air dried for 4 to 6 hours and, thereafter, cured for 7 days after the application of last coat.
(b) For Brush Topping Mix This shall be applied in two coats. A primary coat of slurry mix can also be firstapplied on the surface as first coat. After the coating has dried up, a coat of BrushTopping Mix shall be applied over it with a push broom or any other similar brush. Itshall be left in broom finished condition. The nominal thickness shall be 1.5 mm andminimum thickness shall be 1.0 mm. A lap of 75 mm shall be provided at the joints. Itshall be ensured that no pinhole exists and rebrushing shall be done to cover thepinholes, if any.The Coating shall be air dried for 4 to 6 hours and thereafter cured for 7 days afterthe application of last coat.Rate of application of coating shall be established to achieve the required thickness.
19.0
Architectural Features
All architectural features of buildings like control rooms, M. C. C.rooms, transfer houses and conveyor galleries etc. shall be detailed by contractor’squalified contractor’squalified architect. Necessary projections, fins etc. in addition to the minimumspecified elsewhere in this specification shall be provided as required. The Contractor for Employer/RITES’s approval shall submit detailed architectural drawings along with colour schemes. Nothing extra shall be payable for any changes required while getting the drawings / schemes approved and for executing the same.In case structural column base plates are proposed below the floor level, the same shall be encased with adequate adequate cover up to the finished floor level with minimum M -20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skinreinforcement of the encasing.
20.0
Glazing
Window glazing for various locations shall be as below: (i)In transfer er houses and pump houses etc: Polycarbonate sheet. (ii)In Switchgear / M. C. C. buildings (a) In air conditioned (A / C) areas: Double glazing with two 6 mm thick clear toughened safety glass hermetically sealed and separated by 12 mm thick gap for thermal therma insulation at partition of A / C and non A / C areas. Technical Specification:Sec-7, Civil
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(b) In toilets: Ground glass of minimum thickness 4 mm. (c) In other areas: Toughened glass of minimum thickness 4 mm The above mentioned glass thickness are bare minimum only and actual thickness will depend on the panel size of the glazing to be provided.
21.0
False Ceiling
All air - conditioned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system with corrosion resistance aluminium alloy panels of minimum m thickness 0.5 mm. 50 mm thick mineral wool insulation (as per IS: 8183) having a density of 32 kg/cum for glass wool or 48 kg/cum for rock wool, bound in polythene bags shall be laid on top of panels. Additional hangers and height adjustment clips shall be provided for returns air grills, light fixtures, A. C. ducts etc. Suitable M. S. channel (Minimum ISMC 75) grid shall be provided above the false ceiling level for movement of personnel to facilitate maintenance of lighting fixtures, AC ducts etc. Under deck insulation shall be provided on the ceiling (underside of roof slab) and underside of floor slab of air - conditioned areas depending upon the functional requirements. This under deck insulation shall consist of 50 mm thick mineral wool insulation insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool or 48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 mm mesh wire netting and shall be fixed to the ceiling with 14G wire ties.
22.0
Acid / Alkali Resistant Resis Lining
Battery Room For Floor and dado, bitumen primer followed by 12 mm thick bitumastic 6 mm thick potassium silicate mortar bedding and 20 mm thick A. R. tiles shall be provided. Dado height shall be minimum 2.0 m from floor. M. S. Grating / Chequered Chequered plate cover and any other steel structure likely to come in contact with chemicals shall be provided with epoxy coating 150 microns thick over epoxy primer. Acid / Alkali resistant lining material shall conform to the following: Bitumen primer shall conform conform to IS: 158. Bitumastic compound shall conform to IS: 9510. Where the height of bitumastic layer on vertical surface is more than 2.0 m, the bitumastic layer shall be reinforced with diamond pattern expanded metal steel sheets conforming to IS: 412. A. R. tiles shall conform to IS: 4457. Mortar: Potassium silicate and resin type mortars shall conform to IS : 4832 Parts – I and II respectively.
23.0
FINISHING SCHEDULE
The contractor's scope also includes all doors, windows, glazing, rolling shutters, finishes, f damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings, toe - guards, ladders, edge protection angles, etc. The Contractor shall adhere to the finishing schedule as given.
23.1
Flooring
I. P. S. ( cement concrete flooring ) with metallic hardener topping shall be provided for all floors in transfer houses, including ground floors of transfer houses, ground conveyors, operating floor of pump houses, M. C. C. rooms, cable vault / cable spreader rooms, maintenance enance and unloading areas, general storage areas and all other areas in plant buildings where heavy duty flooring is required. Heavy Duty Ceramic Tiles ( matt finish ) shall be provided for toilets, office rooms, laboratories, control rooms and control equipment eq rooms. Well polished Kota stone shall be provided for staircases, passages, lobbies and general circulation areas. The floor shall be laid on an already laid and matured concrete base. Sunken R. C. C. slab shall be provided in toilet area so as to keep the finished floor level of these areas same as that of the surrounding area Wherever specified metallic hardener topping shall be 12 mm thick using uniformly graded iron particles, properly treated. Wherever specified Heavy duty ceramic tiles of size size 300 x 300 x 7 mm thick (minimum) of reputed manufacturer (Kajaria, Spartek or equivalent) of approved finish, shade and colour to be used. The tiles shall have a scratch resistance of minimum 5 on Mohr’s scale and shall have a bending strength of 350 Kgs. Kgs. / cm.2 Paving details shall be similar to grade slab excluding metallic hardener. Skirting in general shall be 150 mm high. Technical Specification:Sec-7, Civil
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Dado in toilets and pantries shall be up to 2.1 m height from finished floor level. Skirting and dado shall match with the floor finish. f
23.2
Interior Wall / Ceiling Finish
For all air - conditioned areas and stair case acrylic emulsion paint of approved make and shade over 2-3 mm cement based putty of approved make shall be provided. provided For toilets minimum 5 mm thick decorative coloured coloured ceramic tiles of approved make and shade with approved pattern up to 2.10 m. height from finished floor level shall be provided. Oil bound distemper over 2-3 mm cement based putty of approved make above 2.10 m height shall be provided. For all other areas areas oil bound distemper ( IS : 428 ) of approved shade over cement based putty of approved make shall be provided. For battery room and other areas coming in contact with acid / alkali fumes, chemical resistant chlorinated rubber paint shall be provided abovee 2.1 m height. Up to 2.1 m height from finished floor level acid alkali resistant tiles shall be provided as specified elsewhere. All R. C. C. ceilings shall be oil bound distemper over cement based putty. putty
23.3 Exterior Finish Aluminium Industrial troughed sheet cladding ( non - insulated ) of approved colour combination shall be provided for transfer points, conveyor galleries, elevator shafts, and parapet walls of buildings where metal cladding is specified. Exterior weathered coat paint shall be provided for the under mentioned areas : (a) All buildings with R. C. C. framework unless specified otherwise in this specification (b) Brick work in the lower portion of metal cladding. (c) Fire walls Projections and facia : R. C. C. parapets ( excepting parapets of buildings (d) (e) where metal cladding is specified )Exterior brick walls.
24.0DOORS, DOORS, WINDOWS AND ROLLING SHUTTERS. 24.1 Doors and Windows All doors, windows and ventilators venti of control room building and M. C. C. buildings shall have Electro colour coated (anodised) aluminium frame work with glazing. All doors of office and toilet areas shall be of factory made prepre laminated particle board (M D F exterior grade). All other buildings shall have steel doors, windows and ventilators. Single glazed glaz panels with aluminium framework shall be provided as partition between two air - conditioned areas wherever clear view is necessary. Coal conveyor galleries shall have steel windows of openable type. The window shutters shall be provided with M. S. louvers. louv All steel doors shall consist of double plate flush door shutters. The door shutter shall be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom edges of shutters shall be reinforced by continuous pressed steel channel with minimum 18G. The door shall be sound deadened by filling the inside void with mineral wool. Doors shall be complete with all hardware and fixtures like door closer, tower bolts, bolts, handles, stoppers aldrops, etc. Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick wire as per IS: 4948 and 12 mm x 30 mm mesh size. Wherever functionally required rolling shutters shall be provided and these shall be electrically ctrically operated. In transfer points, windows near floors shall be steel and openable types. The window shutters shall be provided with MS louvers. Windows / ventilators at higher level can be of steel with fixed glazing. All openable windows shall be provided ovided with suitable stays. All windows and ventilators onground floor of all switchgear
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and M. C. C. buildings shall be provided with suitable anodized aluminium grill. Fire - Proof doors with panic devices shall be provided at all fire exit points as per per the recommendations of statutory regulatory bodies These doors shall generally be as per IS : 3614 ( Part I and Part II ). Fire rating of the doors shall be as per requirements of statutory regulatory bodies. However minimum rating shall be 2 hours. These These doors shall be double cover-plated cover types with mineral wool insulation. Hollow extruded section of minimum 3 mm wall thickness as manufactured by INDAL or equivalent shall be used for all aluminium doors, windows, and ventilators. Doors and windows on external external walls of the buildings having brick enclosures i.e. enclosure other than with Aluminium Industrial troughed sheet cladding, shall be provided with sunshade over the openings with width 600 mm more than the opening width. Projections from the wall for for the sunshade shall be 450 mm over window openings and 750 mm over door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide, except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those in W/C and urinal areaa ) shall be double plate flush door shutters. For W/C and urinals area, wooden panel doors shall be provided. Area of windows shall be at least 10 % of the floor area of the respective building. The area of translucent polycarbonate sheet panels shall also als be at least 10 % of the floor area of the respective building. Monorail doors shall be provided with steel stays / chains etc for convenient operation of the shutters. The louvre blade shall be ‘Z’ shaped and made out of 18G sheets in EZ7 steel frames. The The frames shall be of ISMC 100.
24.2
Rolling Shutters
Rolling Shutters/ grills shall be with motor drives, gear arrangement including all accessories and shall conform to IS: 6248. All electrical work shall be in strict accordance with the relevant Indian Electricity Rules. After installing the shutters, the Contractor shall test the performance of the shutter in presence of the Engineer. The shutters shall be smoothly operable under all ambient conditions. All control and locking devices shall give fault free f performance. 25.0 PAINTING Painting of all steel structures, including seal plates, hand rails, steel doors & windows, ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc. shall be as per specification mentioned elsewhere in this document. 26.0 Miscellaneous 26.1 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings, pedestals, cable trenches, pits etc., Plywood form work shall be used for all over ground exposed work like columns, beams, floors and and ceilings in control room and M. C. C. buildings. 26.2 Monorail girders and fixtures shall be provided for monorails at the locations as required and as described elsewhere in these specifications or drawings. Monorail openings in the walls shall be provided provided with steel frame doors preferably sliding type or otherwise open able inside, access platforms and ladders. 26.3Steel Steel frame around openings in roof and on external walls for mounting of exhaust fans shall be provided. nk cementitious grout of reputed manufacturer as approved by 26.4 Ready mix non - shrink the Employer shall be used for grouting of block outs and foundation bolts, underpinning of base plates and machine bases. Crushing strength of grout shall be one grade higher than the foundation concrete. Minimum crushing strength shall be 30 N / mm2 unless higher strength requirement is specified by the equipment supplier or the grout manufacturers. 26.5The The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m
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abovee the ground except for rail / road crossing where it shall be 8m above the rail top / road crest/ground. Further in bunker areas it shall be 8 m above the ground. 26.6Polysulphide Polysulphide Sealing Compound shall be two-part two part polysulphide sealant and shall be from om approved manufacturer, conforming to IS : 12118. Materials shall consist of polysulphide polymer and a curing agent. Gun grade material shall be used unless otherwise specified. The application of the sealant shall be strictly followed as per manufacturer’s manufactur guidelines
27.0 SHOTCRETING 27.1 General Requirements 27.2 Generally, shotcreting shall be done in accordance with IS : 9012. 27.3 Reinforcement for shotcreting shall be as detailed below, unless specified otherwise. (i) Reinforcement in one direction direction consisting of 6 mm M. S. bars at 750 mm c / c shall be connected to the lugs for fastening of the wire fabric. This shall be used in case of 50 mm or above thick shotcreting. (ii) Wire fabric conforming to IS : 1566 shall be used as reinforcement and shall sh consist of wire, 3 mm diameter, spaced 50 mm both ways and shall be electrically cross welded. Wire fabric shall be securely tied to 6 mm bars for 50 mm thickness. Adjacent sheet of wire fabric shall be lapped at least 100 mm and tied. (ii) Clear coverr to reinforcement mesh shall not be less than 15 mm. 22.01.03 Minimum thickness of shotcreting shall be 50 mm. for abrasion resistant work and 25mm for ordinary surface protection work.
27.4
Material
Generally, the materials shall be in accordance with with aggregates specification given hereunder. Fine aggregate shall consist of natural sand or crushed stone from a known source and shall be strong, hard, coarse, sharp, chemically inert, clean and free from any coating. It shall be free from clay, coal or coal residue, organic or any other impurities that may impair the strength or durability of the concrete and shall conform to IS :383.Fine aggregate (Sand) shall be well graded and particles shall range in size within the following limits. The Engineer, may ay approved the use of any other grading as per requirement or as erIS : 9012. The fineness modulus shall be preferably between 2.5 and 3.3. Any other value an be used, with prior approval of the Engineer.
27.5
Application
After the placement of reinforcement and / or welded mesh and not more than six ours prior to the application of shotcrete, the surface shall be thoroughly cleaned of all loose aterials and dirt. The Contractor shall properly prepare the surfaces, reinforcement reinfo and / or welded esh to receive the shotcrete. Cleaned surfaces shall be wetted not more than hour prior to hotcreting. The mix as placed on surface shall be one part cement to three parts approved sand by mass. Cement and sand shall be dry mixed; mixed; not water shall be added after mixing and before sing in the gun. The quantity of water when added shall be only that which is sufficient to hydrate the cement. For average atmospheric conditions, the water cement ratio for shotcrete in place shall be between 0.35 and 0.5 by mass.Suitable admixture shall be used wherever required. A uniform pressure of not less than 25 Kgf / Cm2 at the nozzle shall be maintained. Necessary adjustments shall be made to ensure this pressure, taking into account the length of ose and height of the place to be shotcreted, above location of the machine. The application shall proceed in an upward direction. Beams, stiffeners andintermediate walls, if any, shall be wrapped with wire fabric and completely covered with hotcreting. hotcreting All rebound shall be removed from the area of application as the work progresses andsuch rebound material shall not be reused. Technical Specification:Sec-7, Civil
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As soon as the freshly shotcreted surface shows the first dry patches, a fine spray 0f water shall be applied to keep too moist. moist. After the surface has hardened, it shall be kept continuously moist for minimum seven days. If there is extreme heat, especially when ccompanied by hot winds, the shotcreted surface, immediately upon completion, shall be covered with burlap or similar covering, covering, which must be kept continuously moist for 14 days after shotcreting. The temperature of the lining shall not be permitted to exceed 38 oC during placing and curing.
28.0 PTFE (Poly Tetra Fluoroethylene) Bearing The bearing shall be of reputed make and manufacturer as approved by theEngineer, for required vertical load and end displacement/rotation. PTFE bearingshall be sliding against highly polished stainless steel and the coefficient of frictionbetween them shall be less than 0.06 at 55 kg/sq.cm. In order to prevent cold flow inPTFE surface it shall be rigidly bonded by a special high temperature resistanceadhesive to the stainless steel substrata. The stainless steel surface that slidesagainst the PTFE is mirror polished. The stainless steel shall be bonded to the topplate by special high strength adhesive. The thickness of stainless steel plate shallbe between 1.0 mm to 1.5 mm.
29.0
TESTS FOR MATERIAL / WORKMANSHIP
All tests required for all materials, quality of workmanship or any other tests asdesired by the Engineer shall be at contractor’s cost.
30.0 MATERIALS 30.1 For Civil, Structural and Architectural works Employer will not supply any material. All materials including cement, reinforcementsteel and structural steel, whatsoever required for for execution and completion of theentire scope of work covered under this specification shall be arranged by thecontractor at his own cost. All materials procured by the contractor shall meet thequality requirements specified in this specification.The contractor ractor shall keep sufficient stock of cement and steel at site at any point oftime when the work is in progress excluding what has been already incorporated inthe works, so that any disruption / delay in availability of these materials duringprocurement willll not affect the progress of work at site. The minimum quantity ofsuch materials in stock at site shall not be less then the Requirement of one( 1 )month in case of Cement and Requirement of two ( 2 ) Consecutive months in caseof Steel.
30.2 Cement The contractor shall use cements conforming to, IS: 455, IS: 8112. Higher grade of cement namely GR - 53 of ordinary portland cement conforming to IS: 12269 can also be used. 30.3 Reinforcement steel shall conform to: to a) Mild steel grade I of IS: 432 Part – I and grade A of IS: 2062. b) High yield deformed bar of IS: 1786 (Gr. Fe 415 and Fe. 500). 30.4 Structural steel: olled sections and plate shall conform to Grade A as per IS: 2062-1992 2062 1992 and/or as per Rolled specification specified at relevant clauses. clauses
31.0
Guarantee for water proofing
The contractor shall furnish guarantee for the water proofing or similsr work wherever it is included in civil work for three years. The contractor shall furnish a Bank Guarantee equivalent to 105 of the value of water proofing work to be valid additional two years beyond the defect liability period of the contract. The BG/SD towards the defect liability period can be returned only on submission of bank guarantee for water proofing as stated above.
32.0
CODES AND STANDARDS
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All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. Other Indian, foreign Codes and Standards not listed here but referred to elsewhere within this thi specification shall also be deemed to be part of this list. In case of conflict between this specification and those (IS standards, codes etc.) referred to herein, the former shall prevail. Some of the relevant Indian standards, Acts and Codes applicable to this section of the specification are listed below IS : 383 Specification for coarse and fine aggregates from natural sources for Concrete. IS : 432 Specification for mild steel and medium tensile steel bars and hard drawn steel wire for concrete reinforcement. nforcement. IS : 456 Code of practice for plain and reinforced concrete. IS : 458 Specification for concrete pipes. IS : 516 Method of test for strength of concrete. IS : 800 Code of practice for use of structural steel in general building construction. construction IS : 814 Specification for covered electrodes for metal arc welding for weld steel. IS : 816 Code of practice for use of metal arc welding for general construction. IS : 817 Code of practice for training and testing of metal arc welders. IS : 875 (Pt. I to V) Code of practice for design loads other than earthquake) for buildings and structures. IS : 1038 Steel doors, windows and ventilators. IS : 1172 Basic requirements for water supply, drainage and sanitation. IS : 1361 Steel windows ows for industrial buildings. IS : 1786 Specification for high strength deformed steel bars and wires for concrete reinforcement. IS : 1892 Code of practice for subsurface investigation for foundation. IS : 1893 Criteria for earthquake resistant design of structures. IS : 1904 Code of practice for design and construction of foundations in soils; general requirements IS : 1905 Code of practice for structural safety of buildings -Masonry Masonry walls. IS : 1948 Specification for aluminium doors, windows and ventilators. IS : 2062 Steel for general structural purposes. IS : 2131 Method of standard penetration test for soils. IS : 2212 Code of practice for brickwork. IS : 2645 Specification for Integral cement water proofing compounds. IS:2720 (Part-II, Methods ethods of test for soils - determination for water content IV TO VIII, XIV, etc code of practice for earth work on canals. XXI, XXIII, XXIV, XXVII TO XXIX, XL) IS : 2911 Code of practice for design and construction of pile foundations. (Part-1/Sec.1) Driven iven cast in situ concrete piles. (Part-1/Sec.2) (Part 1/Sec.2) Bored cast-in-situ cast concrete piles. (Part-IV) IV) Load test on piles. IS : 2974 (Part – I Code of practice for design and construction of machine TO V) foundations. IS : 3370 (Part I to Code of practice for concrete concrete structures for the storage of IV) liquids. IS : 3658 Code of practice for liquid penetrant flaw detection. IS : 3664 Code of practice for ultra sonic testing by pulse echo method. IS : 4326 Code of practice for earthquake resistant design and construction construction of buildings. IS : 4990 Specification for plywood for concrete shuttering work. IS : 5624 Specification for foundation bolts. IS : 7215 Tolerances for fabrication steel structures. IS : 8112 Specification for 43 grade Ordinary Portland Cement. Cement IS : 9103 Specification for admixtures for concrete. Technical Specification:Sec-7, Civil
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IS : 9595 Code of procedure of manual metal arc welding of mild steel. IS : 10262 Recommended guidelines for concrete mix design IS : 13311 Method of non - destructive testing of concrete. IS : 13755 Dust pressed ceramic tiles with water absorption of 3%,E6% (Group B11a) ASTM 898 -89 89 Standard guide for use of high solid content, cold liquidliquid-applied elastomeric water proofing membrane for use with separate wearing course. AS/NZS 2728 Pre finished finis / pre painted sheet metal product for interior / exterior building applications – Performance requirements. AS : 1365 Standards for steel manufacturing. AS : 1397 A steel sheet & strip – hot – dipped-zinc-coated or Aluminium--Zinc coated. AS : 3566 Self drilling screws for building and construction industry. IRC : 37 Guidelines for the design of flexible pavements. - Manual on sewerage and sewage treatment (Published by CPH & EEO) As updated. Indian Explosives Act. 1940 as updated
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SECTION 8 1.0
GENERAL
1.1
The following provisions shall supplement the conditions already contained in the other parts of these specifications and documents and shall govern that portion of the work of this contract which is to be performed at site. The erection requirements and procedures not specified in these documents shall be in accordance with the recommendations of the equipment manufacturer, or as mutually agreed to between the Employer and the Contractor prior to commencement of erection work.
1.2
The Contractor upon signing of the Contract shall, in addition to a Project Coordinator, nominate another responsible officer as his representative at Site suitably designated for fo the purpose of overall responsibility and co-ordination co ordination of the Works to be performed at Site. Such a person shall function from the Site office of the Contractor during the pendency of Contract.
2.0
REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.0.1 In n addition to the local laws and regulations, the Contractor shall also comply with the Minimum Wages Act and the Payment of Wages Act (both of the Government of India) and the rules made there under in respect of its labour and the labour of its sub-contractors sub currently employed on or connected with the contract. 2.0.2 All registration and statutory inspection fees, if any, in respect of his work pursuant to this Contract shall be to the account of the Contractor. However, any registration, statutory inspection pection fees lawfully payable under the provisions of the Indian Boiler Regulations and any other statutory laws and its amendments from time to time during erection in respect of the plant equipment ultimately to be owned by the Employer, shall be to the account of the Employer. Should any such inspection or registration need to be re-arranged re arranged due to the fault of the Contractor or his Sub-Contractor, Sub Contractor, the additional fees for such inspection and/or registration shall be borne by the Contractor. 2.1
ation of Weld Procedures Qualification Only qualified welding procedures as per ASME Section IX shall be used by contractor at site. Procedure qualification records along with WPS shall be submitted to NALCO for review. Welding procedure shall indicate all essential and a non-essential essential parameters as per ASME Section IX. Makes of welding consumables shall be subject to employer’s approval.
3.0
SITE RUN MISCELLANEOUS PIPING Sketches or diagrams of the proposed routings of all piping, not already indicated and routed on the shop drawings which were reviewed by the Employer, shall be submitted to the
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Employer for review, Employer's acceptance of such site routings shall be obtained obta before the piping is erected. All these site run piping shall be installed in such a manner as to present an orderly and neat installation. They shall be located as to avoid obstruction of access and passages. Valves, instruments or any other special items shall be located convenient for operation by the operating personnel. Pipe runs shall be plumb or level except where pitch for drainage is required. Pipe runs that are not parallel to the building structure, walls or column rows shall be avoided. No miscellaneous pipe shall be routed and installed above or adjacent to electrical equipment. 4.0
PIPING SUPPORTS
4.1
Hangers, supports and anchors shall be installed as required to obtain a safe, reliable and complete pipe installation. All supports shall be properly levelled and anchored when installed. The anchors shall be so placed that thermal expansion will be absorbed by bends without subjecting the valves or equipment to excessive strains.
4.2
The hanger assemblies shall not be used for the attachment attachment of rigging to hoist the pipe into place. Other means shall be used to securely hold the pipe in place till the pipe support is completely assembled and attached to the pipe and building structures and spring support is set to accommodate the pipe way. All temporary rigging shall be removed in such a way that the pipe support is not subjected to any sudden load. All piping, having variable spring type supports, shall be held securely in place by temporary means during the hydraulic test of pipe system. Constant onstant support type spring hangers used during hydraulic test shall be pinned or blocked solid during the test. After complete installation and insulation of the piping and filling of the piping with its normal operating medium, the pipe support springs shall s be adjusted to the cold positions. If necessary, the spring support shall be re-adjusted re adjusted to the hot positions after the line has been placed for service at its normal maximum operating temperature conditions. Electric arc welding only shall be used to weld all pipe supports to structural steel members that form part of the building supporting structure. The structural beams shall not be heated more than necessary during welding of supports and such welds shall run parallel to the axis of the span. All lugs or any other attachments welded to the piping shall be of the same material as the pipe.
5.0
CODE REQUIREMENTS The erection requirements and procedures to be followed during the installation of the equipment shall be in accordance with the relevant Indian Electricity Rules & Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the Employer's Drawings and other applicable Indian recognised codes and laws and regulations of the Government of India.
6.0
ELECTRICAL SAFETY REGULATIONS REGULATION
6.1
In no circumstances will the Contractor interfere with fuses and electrical equipment belonging to the other Contractor or Employer.
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6.2
Before the Contractor connects any electrical appliances to any plug or socket belonging to the other Contractor or Employer, he shall: a) Satisfy the Employer that the appliance is in good working condition; b) Inform the Employer of the maximum current rating, voltage and phases of the appliances; appli may c) Obtain permission of the Employer detailing the socket to which the appliances be connected.
6.3
No repair work shall be carried out on any live equipment. The equipment must be declared safe by the Employer and a permit to work issued before any work is carried out.
6.4
The Contractor shall employ the necessary number of qualified, full time electricians to maintain his temporary electrical installation.
7.0
REMOVAL OF MATERIAL No material brought to the Site shall be removed from the Site by the Contractor and/or his Sub-Contractors Contractors without the prior written approval of the Employer.
8.0
INSPECTION, TESTING AND INSPECTION CERTIFICATES The provisions of the clause entitled Inspection, Testing and Inspection Certificates given in General Technical Requirement, shall also be applicable to the erection portion of the Works. The Employer shall have the right to re-inspect re inspect any equipment though previously inspected and approved by him at the Contractor’s works, before and after the same are erected at Site. If by the above inspection, the Employer rejects any equipment, the the Contractor shall make good for such rejections either by replacement or modification/ repairs as may be necessary to the satisfaction of the Employer. Such replacements will also include the replacements or re-execution execution of such of those works of other Contractors Contractors and/or agencies, which might have got damaged or affected by the replacements or re-work re work done to the Contractor’s work.
9.0
ACCESS TO SITE AND WORKS ON SITE
9.1
Suitable access to site and permission to work at the Site shall be accorded to the th Contractor by the Employer in reasonable time.
9.2
In the execution of the Works, no person other than the Contractor or his duly appointed representative, Sub-Contractor Contractor and workmen, shall be allowed to do work on the Site, except by the special permission, sion, in writing by the Employer or his representative.
10.0 CONTRACTOR’S SITE OFFICE ESTABLISHMENT The Contractor shall establish a Office at the Site and keep posted an authorized representative for the purpose of the Contract. Any written order or instruction of the Employer or his duly authorised representative, shall be communicated to the said authorised Technical Specification:Sec-8l
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resident representative of of the Contractor and the same shall be deemed to have been communicated to the Contractor at his legal address. OPERATION WITH OTHER CONTRACTORS 11.0 CO-OPERATION operate with all other Contractors or tradesmen of the Employer, who 11.1 The Contractor shall co-operate may be performing other works on behalf of the Employer and the workmen who may be employed by the Employer and doing work in the vicinity of the works under the Contract. The Contractor shall also arrange to perform his work as to minimise, to the maximum extent ex possible, interference with the work of other Contracts and their workmen. Any injury or damage that may be sustained by the employees of the other Contractors and the Employer, due to the Contractor’s work shall promptly be made good at his own expense. expen The Employer shall determine the resolution of any difference or conflict that may arise between the Contractor and other Contractors or between the Contractor and the workmen of the Employer in regard to their work. If the work of the Contractor is delayed delayed because of the any acts of omission of another Contractor, the Contractor shall have no claim against the Employer on that account other than an extension of time for completing his works. Employer shall have full access to visit the contractor’s site site at any time for inspection and surveillance checks. 11.2 The Employer shall be notified promptly by the Contractor of any defects in the other Contractor’s works that could affect the Contractor’s Works. The Employer shall determine the corrective measures res if any, required to rectify this situation after inspection of the works and such decisions by the Employer shall be binding on the Contractor. 12.0 DISCIPLINE OF WORKMEN The Contractor shall adhere to the disciplinary procedure set by the Employer in i respect of his employees and workmen at Site. The Employer shall be at liberty to object to the presence of any representative or employee of the Contractor at the Site, if in the opinion of the Employer such employee has mis-conducted mis himself or is incompetent, mpetent, negligent or otherwise undesirable then the Contractor shall remove such a person objected to and provide in his place a competent replacement. 13.0 CONTRACTOR’S FIELD OPERATION 13.1 The Contractor shall keep the Employer informed in advance regarding his field activity plans and schedules for carrying out each part of the works. Any review of such plan or schedule or method of work by the Employer shall not relieve the Contractor of any of his responsibilities towards the field activities. Such Such reviews shall also not be considered as an assumption of any risk or liability by the Employer or any of his representatives and no claim of the Contractor will be entertained because of the failure or inefficiency of any such plan or schedule or method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy and efficiency of plant and equipment and his erection methods.
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13.2 The Contractor shall have the complete responsibility for the conditions of the WorkWork Site includingg the safety of all persons employed by him or his Sub-Contractor Sub Contractor and all the properties under his custody during the performance of the work. This requirement shall apply continuously till the completion of the Contract and shall not be limited to normal working hours. The construction review by the Employer is not intended to include review of Contractor’s safety measures in, on or near the WorkWork Site, and their adequacy or otherwise. 14.0 PHOTOGRAPHS AND PROGRESS REPORT 14.1 The Contractor shall furnish furnish three (3) prints each to the Employer of progress photographs of the work done at Site. Photographs shall be taken as and when indicated by the Employer or his representative. Photographs shall be adequate in size and number to indicate various stages of erection. Each photograph shall contain the date, the name of the Contractor and the title of the photograph. 14.2 The above photographs shall accompany the monthly progress report detailing out the progress achieved on all erection activities as compared compared to the schedules. The report shall also indicate the reasons for the variance between the scheduled and actual progress and the action proposed for corrective measures, wherever necessary. 14.3 The Contractor shall submit the progress of work in video cassettes cassettes (2 copies) quarterly highlighting the progress and constraints at site. 15.0 MAN-POWER REPORT 15.1 The Contractor shall submit to the Employer, on the first day of every month, a man hour schedule for the month, detailing the man hours scheduled for the month, skill-wise skill and areawise. 15.2 The Contractor shall also submit to the Employer on the first day of every month, a man power report of the previous month detailing the number of persons scheduled to have been employed and actually employed, skill- wise and the areas of employment of such labour. 16.0 PROTECTION OF WORK The Contractor shall have total responsibility for protecting his works till it is finally taken over by the Employer. No claim will be entertained by the Employer or the representative of the Employer for any damage or loss to the Contractor’s works and the the Contractor shall be responsible for complete restoration of the damaged works to original conditions to comply with the specification and drawings. Should any such damage to the Contractor’s Works occur because of other party not being under his supervision supervision or control, the Contractor shall make his claim directly with the party concerned. If disagreement or conflict or dispute develops between the Contractor and the other party or parties concerned regarding the responsibility for damage to the Contractor’s Contractor’s Works the same shall be resolved as per the provisions of the as specified at clause no 11 of this chapter entitled “Co-operation “Co operation with other Contractors.” The Contractor shall not cause any delay in the repair of such damaged Works because of any Technical Specification:Sec-8l
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delay in the resolution of such disputes. The Contractor shall proceed to repair the Work immediately and no cause thereof will be assigned pending resolution of such disputes. 17.0 EMPLOYMENT OF LABOUR In addition to all local laws and regulations pertaining to the employment of labour to be complied with by the Contractor pursuant to GCC, the Contractor will be expected to employ on the work only his regular skilled employees with experience of the particular work. No female labour shall be employed employed after darkness. No person below the age of eighteen years shall be employed. All travelling expenses including provisions of all necessary transport to and from Site, lodging allowances and other payments to the Contractor’s employees shall be the sole responsibility of the Contractor. The hours of work on the Site shall be decided by the Employer and the Contractor shall adhere to it. Working hours will normally be eight (8) hours per day – Monday through Saturday. Contractor’s employees shall wear identification identification badges while on work at Site. In case the Employer becomes liable to pay any wages or dues to the labour or any Government agency under any of the provisions of the Minimum Wages Act, Workmen Compensation Act, Contact Labour Regulation Abolition Abolition Act or any other law due to act of omission by the Contractor, the Employer may make such payments and shall recover the same from the Contractor’s payments. 18.0 FACILITIES TO BE PROVIDED BY THE EMPLOYER 18.1 Space The Contractor shall advise the Employer Employer within thirty (30) days from the date of acceptance of the Notification of Award about his exact requirement of space for his office, storage area, pre-assembly assembly and fabrication areas, labour and staff colony area, etc. The above requirement shall be reviewed by the Employer and space as decided by Employer will be allotted to the Contractor for construction of his temporary structures/ facilities like office, storage sheds, pre-assembly assembly and fabrication areas, labour and staff colony, toilets, etc. for Contractor's as well as his Sub-Contractor’s Contractor’s use. 18.2 Electricity The Contractor shall submit to the Employer within thirty (30) days from the date of acceptance of the Notification of Award, his electrical power requirements, if any, to allow the planning anning of the same by the Employer. The Contractor shall be provided with supply of electricity on chargeable basis for the purposes of the Contract, only at two locations in the Employer’s Site and at 415V level. The Contractor shall make his own further distribution arrangement. All temporary wiring must comply with local regulations and will be subject to Employer’s inspection and approval before connection to supply. The free supply of power will not be provided for the use in the labour and staff colony. colony. Power supply for labour and staff colony shall be provided at one point and the Contractor shall be charged at rates prevalent at Technical Specification:Sec-8l
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the site. Illumination of wagon tippler and the conveyor area shall be the scope of the tenderer. 18.3 Water Contractor shall make all arrangements himself for the supply of construction water as well as potable water for labour and other personnel at the worksite/colony. 18.4 Communication The Employer will extend the telephone facilities, if available at Site, for purposes purpos of Contract. The Contractor shall be charged at actuals for such facilities. 19.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 19.1 Contractor's site office Establishment The Contractor shall establish a site office at the site and keep posted an authorized autho representative for the purpose of the contract, pursuant to GCC. 19.2 Tools, tackles and scaffoldings The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings required for pre-assembly, assembly, installation, testing, commissioning and conducting Guarantee tests of the equipments covered under the Contract. He shall submit a list of all such materials to the Employer before the commencement of preassembly at Site. These tools and tackles shall not be removed from the Site Site without the written permission of the Employer. The Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning. 19.3 Testing Equipment and Facilities: The contractor shall provide the necessary necessary testing, equipment and facilities. 19.4 Site laboratory for civil works: Contractor shall provide and maintain a site laboratory for the testing of construction material under the direction and general supervision of employer. 19.5 First-aid 19.5.1 The Contractor shall provide necessary first-aid first aid facilities for all his employees, representatives and workmen working at the Site. Enough number of Contractor’s personnel shall be trained in administering first-aid. Contractor, in case of any emergency, the services of an 19.5.2 The Employer will provide the Contractor, ambulance for transportation to the nearest hospital. 19.6 Cleanliness 19.6.1 The Contractor shall be responsible for keeping the entire area allotted to him clean and free from rubbish, debris etc. during the period of Contract. The Contractor shall employ enough number of special personnel to thoroughly clean his work-area work area at least once in a day. All such rubbish and scrap material shall be stacked or disposed in a place to be identified by the Technical Specification:Sec-8l
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Employer. oyer. Materials and stores shall be so arranged to permit easy cleaning of the area. In areas where equipment might drip oil and cause damage to the floor surface, a suitable protective cover of a flame resistant, oil proof sheet shall be provided to protect prote the floor from such damage. 19.6.2 Similarly the labour colony, the offices and the residential areas of the Contractor’s employees and workmen shall be kept clean and neat to the entire satisfaction of the Employer. Proper sanitary arrangements shall be be provided by the Contractor, in the workwork areas, office and residential areas of the Contractor. 20.0 LINES AND GRADES All the Works shall be performed to the lines, grades and elevations indicated on the drawings. The Contractor shall be responsible to locate and layout the Works. Basic horizontal and vertical control points will be established and marked by the Employer at Site at suitable points. These points shall be used as datum for the works under the Contract. The Contractor shall inform the Employer yer well in advance of the times and places at which he wishes to do work in the area allotted to him so that suitable datum points may be established and checked by the Employer to enable the Contractor to proceed with his works. Any work done without being ng properly located may be removed and/or dismantled by the Employer at Contractor’s expense. 21.0 FIRE PROTECTION 21.1 The work procedures that are to be used during the erection shall be those which minimise fire hazards to the extent practicable. Combustible Combustible materials, combustible waste and rubbish shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or flammable materials shall be stored away from the construction and equipment and materials storage areas in safe fe containers. Untreated canvas, paper, plastic or other flammable flexible materials shall not at all be used at Site for any other purpose unless otherwise specified. If any such materials are received with the equipment at the Site, the same shall be removed re and replaced with acceptable material before moving into the construction or storage area. 21.2 Similarly corrugated paper fabricated cartons etc. will not be permitted in the construction area either for storage or for handling of materials. All such materials used shall be of water proof and flame resistant type. All the other materials such as working drawings, plans etc. which are combustible but are essential for the works to be executed shall be protected against combustion resulting from welding welding sparks, cutting flames and other similar fire sources. 21.3 All the Contractor’s supervisory personnel and sufficient number of workers shall be trained for fire-fighting fighting and shall be assigned specific fire protection duties. Enough of such trained personnel ersonnel must be available at the Site during the entire period of the Contract.
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21.4 The Contractor shall provide enough fire protection equipment of the types and number for the warehouses, office, temporary structures, labour colony area etc. Access to such fire protection equipment, shall be easy and kept open at all time. 22.0 SECURITY The Contractor shall have total responsibility for all equipment and materials in his custody stores, loose, semi-assembled assembled and/or erected by him at Site. The Contractor Contrac shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. All materials of the Contractor shall enter and leave the Employer Site only with the written permission of the Employer in the prescribed manner. 23.0 CONTRACTOR’S AREA LIMITS out the boundary limits of access roads, parking spaces, storage and The Employer will mark-out construction areas for the Contractor and the Contractor and his personnel shall not trespass the areas into other areas of the plant. In case of a need for the Contactor’s personnel to work in the areas beyond that marked out for him, the same shall be done only with the written permission of the Employer. OPERATION WITH THE EMPLOYER 24.0 CONTRACTOR’S CO-OPERATION In case where the performance of the erection work by the Contractor affects the operation of the system facilities of the Employer, such erection work of the Contractor shall be scheduled to be performed only in the manner stipulated by the Employer and the same shall be acceptable at all times to the Contractor. The Employer may impose such restrictions on the facilities provided to the Contractor such as electricity, etc. as he may think fit in the interest of the Employer and the Contractor shall strictly adhere to such restrictions and co-operate co with the Employer. It will be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up start and operation of the equipment systems which are erected by him. The Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants required for the equipment furnished and installed by him, so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants. COMMISSIONING AND COMMISSIONING ACTIVITIES 25.0 PRE-COMMISSIONING (a)
GENERAL The Contractor upon completion of installation of equipments and systems, shall conduct pre-commissioning commissioning and commissioning activities, to make the equipment/systems ready for safe, reliable and efficient operation on sustained basis. All pre precommissioning/commissioning /commissioning activities considered essential for such readiness of the equipment/systems including those mutually agreed and included in the Contractor’s quality
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assurance programme as well as those indicated in clauses elsewhere in the technical specifications cations shall be performed by the contractor. (b)
commissioning and commissioning activities including Guarantee tests, checks and The pre-commissioning trial operations of the equipment/systems furnished and installed by the contractor shall be the responsibility of the he Contractor as detailed in relevant clauses in Technical Specification. The Contractor shall provide, in addition, test instruments, calibrating devices etc. and labour required for successful performance of these operations. If it is anticipated that the th above test may prolong for a long time, the Contractor’s workmen required for the above test shall always be present at site during such operations.
(c)
The following activities shall be carried out by the contractor, prior to schedule date of commissioning ioning of the equipment/systems installed by him. The contractor shall furnish the organization chart of his operation and commissioning engineers for the acceptance of employer. Adequate number of operation and commissioning engineers shall be deployed deployed by the contractor to effectively meet the requirement of round the clock operation in shifts also, till the plant is taken over by the employer. (ii) The contractor shall submit the bio-data bio data containing the details of experience of his operation and commissioning mmissioning engineers for the acceptance of employer. (iii) The contractor shall furnish the deployment schedule of his operation and commissioning engineers for the acceptance of the employer. (iv) Apart from above, contractor shall ensure deployment of sufficientskilled/semisufficientskilled/semi skilled/unskilled manpower during pre-commissioning pre commissioning and commissioning activities. (i)
(d)
It shall be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up s up and initial operation of the equipment/systems which are installed by him.
(e)
The Contractor shall also be responsible for flushing and initial filling of all oils and lubricants required for the equipment furnished and installed by him so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in these specifications and documents.
26.0 COMMISSIONING DOCUMENTATION (a) The contractor shall submit the commissioning documentation, comprising of Standard checklists, pre-commissioning commissioning procedures, testing schedules, commissioning schedules and commissioning networks for various equipment/systems covered under the contract, for f the approval of employer. (b) Standard checklist, as the name suggests, shall be a fairly general documents, containing the list of all checks required to be carried out for similar and repetitive type of equipment to ensure consistent and thorough checking. Technical Specification:Sec-8l
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shall be prepared for systematic commissioning of individual (c) The testing schedule shall equipment/sub-system system Commissioning. The format of testing/Commissioning schedule shall be such as to maintain consistency of presentation, content and reporting list of commissioning documentation to be submitted by (d) The contractor shall submit the list him, alongwith their submission schedule for various equipment/systems covered under the contract, with in 6(six) month from the date of award of contract, for the acceptance of employer. (e) The Contractorr shall submit the commissioning documentation, for various equipment/covered under the contract, for the approval of employer, at least 18 months before the scheduled date of commissioning of the equipment/systems. 27.0
COMMISSIONING ACTIVITIES ompletion of pre-commissioning pre commissioning activities/tests, the contractor shall initiate (a) Upon completion commissioning of facilities. During commissioning the Contractor shall carry out system checking and reliability trials on various sub-systems sub of the facilities. (b) Contractor shall carry out the checks/tests at site to demonstrate to the Employer that each of the equipment of the supplied complies with requirements stipulated and is installed in accordance with requirements specified. Before the plant is put into initial operation operation the Contractor shall be required to conduct (c) test to demonstrate to the Employer that each item of the plant is capable of correctly performing the functions for which it was specified and its performance, parameters etc. are as per the specified/approved specified/approved values. These tests may be conducted concurrently with those required under commissioning sequence. (d) Other tests shall be conducted, if required by the Employer, to establish that the plant equipment are in accordance with requirements of the specifications. specifica The Contractor shall conduct all the commissioning tests and undertake commissioning (e) activities pertaining to all other auxiliaries and equipments including all electrical equipment/systems not specifically brought out above but are within the scope sco of work and facilities being supplied and installed by the Contractor and follow the guidelines indicated above or elsewhere in these technical specifications(Sectionspecifications(Section VI) (f)
Initial Operation
Upon completion of system checking/Tests as above and as a part part of commissioning of facilities, complete plant/facilities shall be put into initial operation as stipulated in General Technical Requirements.
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28.0 MATERIALS HANDLING AND STORAGE (a) All the equipments furnished under the Contract and arriving at Site shall be promptly received, unloaded and transported and stored by the Contractor. (b) Contractor shall be responsible for examining all the shipment and notify the Employer immediately of any damage, shortage, discrepancy etc. for the purpose of Employer's Employe information only. The Contractor shall submit to the Employer every week a report detailing all the receipts during the week. However, the Contractor shall be solely responsible for any shortages or damage in transit, handling and / or in storage and erection erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. (c) The Contractor shall maintain an accurate and exhaustive record detailing out the list of all equipment received by him for the purpose of erection and keep such record available for the inspection of the Employer. (d) All equipment shall be handled with care to prevent any damage. No bare wire ropes, slings, etc. shall be used for unloading unloading and/or handling of the equipment without the specific written permission of the Employer. The equipment stored shall be properly protected to prevent damage to the equipment. The equipment from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such equipment at Site. (e) All electrical panels, controls gear, motors and such other devices shall be properly dried by heating before they are installed and energised. Motor bearings, slip rings, commutators and nd other exposed parts shall be protected against moisture ingress and corrosion during storage and periodically inspected. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent corrosion due to prolonged storage. ontractor shall ensure that all the packing materials and protection devices used for (f) The Contractor the various equipments during transit and storage are removed before the equipment are installed. (g) The consumables and other supplies likely to deteriorate due to storage sto must be thoroughly protected and stored in a suitable manner to prevent damage or deterioration in quality by storage. (h) All the materials stored in the open or dusty location must be covered with suitable weatherproof and flameproof covering material mater wherever applicable. (i) If the materials belonging to the Contractor are stored in areas other than those earmarked for him, the Employer will have the right to get it moved to the area earmarked for the Contractor at the Contractor’s cost.
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(j) The Contractor shall be responsible for making suitable indoor storage facilities to store all equipment which require indoor storage. Normally, all the electrical equipments such as motors, control gear, exciters and consumables like electrodes, lubricants lubricants etc. shall be stored in the closed storage space . The Employer, in addition, may direct the Contractor to move certain other materials, which in his opinion will require indoor storage, to indoor storage areas which the Contractor shall strictly comply with. 29.0 CONSTRUCTION MANAGEMENT (a) The field activities of the Contractors working at Site, will be coordinated by the Employer and the Employer decision shall be final in resolving any disputes or conflicts between the Contractor and other Contractors Contractors and tradesmen of the Employer regarding scheduling and co- ordination of work. Such decision by the Employer shall not be a cause for extra compensation or extension of time for the Contractor. Contractors working at Site, at a time (b) The Employer shall hold weekly meetings of all the Contractors and place to be designated by the Employer. The Contractor shall attend such meetings and take notes of discussions during the meeting and the decisions of the Employer and shall strictly adhere to those decisions in performing performing his Works. In addition to the above weekly meeting, the Employer may call for other meeting either with individual Contractors or with selected number of Contractors and in such a case the Contractor if called, will also attend such meetings. (c) Time is the essence of the Contract and the Contractor shall be responsible for performance of his works in accordance with the specified construction schedule. If at any time, the Contractor is falling behind the schedule, he shall take necessary action to t make good for such delays by increasing his work force or by working overtime or otherwise accelerate the progress of the work to comply with the schedule and shall communicate such actions in writing to the Employer, satisfying that his action will compensate compensate for the delay. The Contractor shall not be allowed any extra compensation for such action. (d) The Employer shall however not be responsible for provision of additional labour and/or materials or supply or any other services to the Contractor except except for the coordination work with other Contractors, if necessary. 30.0 FIELD OFFICE RECORDS The Contractor shall maintain at his Site Office up-toup date copies of all drawings, specifications and other Contract Documents and any other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain in addition the continuous record of all changes to the above Contract Documents, drawings, specifications, supplementary data, etc. effected at the field and on completion of his total assignment under the Contract shall incorporate all such changes on the drawings and other Engineering data to indicate as installed conditions of the equipment furnished and erected under the Contract.
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Such drawings and Engineering data shall be submitted to the Employer in requisite number of copies. 31.0 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE (a) The Contractor shall bring to Site all equipment, components, parts, materials, including construction equipment, tools and tackles for the purpose of the Works under intimation to the Employer. All such goods shall, from the time of their being brought vest in the Employer, but may be used for the purpose of the Works only and shall not on any account be removed or taken away by the Contractor Contractor without the written permission of the Employer. The Contractor shall nevertheless be solely liable and responsible for any loss or destruction thereof and damage thereto. (b) The Employer shall have a lien on such goods for any sum or sums which may at any time be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract. After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be at liberty to sell and dispose off any such goods, in such manner as he shall think fit including public auction or private treaty and to apply the proceeds in or towards the satisfaction of such sum or sums due as aforesaid. (c) After the completion of the Works, the Contractor shall remove from the Site under u the direction of the Employer the materials such as construction equipment, erection tools and tackles, scaffolding etc. with the written permission of the Employer. If the Contractor fails to remove such materials, within fifteen (15) days of issue of of a notice by the Employer to do so then the Employer shall have the liberty to dispose off such materials as detailed under as specified at clause no 31 (b) above and credit the proceeds thereto to the account of the Contractor. TY AND CONTRACTOR’SLIABILITY 32.0 PROTECTION OF PROPERTY (a) The Contractor shall be responsible for any damage resulting from his operations. He shall also be responsible for protection of all persons including members of public and employees of the Employer and the employees of other other Contractors and SubSub Contractors and all public and private property including structures, building, other plants and equipments and utilities either above or below the ground. (b) The Contractor will ensure provision of necessary safety equipment such as barriers, sign - boards, warning lights and alarms, etc. to provide adequate protection to persons and property. The Contractor shall be responsible to give reasonable notice to the Employer and the Employers of public or private property and utilities utilities when such property and utilities are likely to get damaged or injured during the performance of his Works and shall make all necessary arrangements with such Employers, related to removal and/or replacement or protection of such property and utilities. utilities
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33.0 PAINTING All exposed metal parts of the equipment including pipings, structure railings, etc. wherever applicable, after installation unless otherwise surface protected, shall be first painted with at least two coats of suitable primer which matches matches the shop primer paint used, after throughly cleaning all such parts of all dirt, rust, scales, greases, oils and other foreign materials by wire brushing, scraping or sand blasting and the same being inspected and approved by the Employer/RITES for painting. nting. Afterwards, the above parts shall be finished painted with two t coats of synthetic enamel paint. paint. The minimum thickness of paint film shall not be less than 100 microns. The quality of the finish paint shall be as per the standards of Bureau of Indian Standards (BIS) or equivalent and to be of the colour as approved by the Employer. 34.0 INSURANCE 34.1 In addition to the conditions covered under the Clause entitled “Insurance” in Section General Conditions of Contract (GCC), the following provisions will also apply to the portion of works to be done beyond the Contractor’s own or his Sub-Contractor’s Sub Contractor’s manufacturing Works. 34.2 Workmen’s Compensation Insurance This insurance shall protect the Contractor against all claims applicable under the Workmen’s Workmen’ Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor against claims for injury, disability disease or death of his or his Sub-Contractor’s Sub Contractor’s employees, which for any reason are not covered under the Workmen’s Compensation Compensati Act, 1948. The liabilities shall not be less than the following: Workmen's Compensation - As per Statutory Provisions Employee's Liability - As per Statutory Provisions Property Damage: Rs.100,000 for each occurrence 34.3 Comprehensive General Liability Insurance 34.3.1 The insurance shall protect the Contractor against all claims arising from injuries, disabilities, disease or death of members of public or damage to property of others, due to any act or omission on the part of the Contractor, his agents, his employees, his representatives and Sub-Contractors Contractors or from riots, strikes and civil commotion. This insurance shall also cover all the liabilities of the Contractor arising out of the Clause entitled “Defence of Suits” in Section General Conditions nditions of Contract (GCC). 34.3.2 The hazards to be covered will pertain to all the Works and areas where the Contractor, his Sub-Contractors, Contractors, his agents and his employees have to perform work pursuant to the Contract. illustrative list of insurance covers normally required and it will be the 34.4 The above are only illustrative responsibility of the Contractor to maintain all necessary insurance coverage to the extent
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both in time and amount to take care of all his liabilities either direct or indirect, in pursuance pursuanc of the Contract. 35.0 UNFAVOURABLE WORKING CONDITIONS The Contractor shall confine all his field operations to those works which can be performed without subjecting the equipment and materials to adverse effects during inclement weather conditions, likee monsoon, storms, etc. and during other unfavourable construction conditions. No field activities shall be performed by the Contractor under conditions which might adversely affect the quality and efficiency thereof, unless special precautions or measures are taken by the Contractor in a proper and satisfactory manner in the performance of such Works and with the concurrence of the Employer. Such unfavourable construction conditions will in no way relieve the Contractor of his responsibility to perform the Works as per the schedule. 36.0 PROTECTION OF MONUMENTS AND REFERENCE POINTS The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. which he may come across during the course of performance of his Works either during excavation or elsewhere, are properly protected and handed over to the Employer. Similarly the Contractor shall ensure that the bench marks, reference points, etc., which are marked either with the help of Employer or by the Employer shall not be disturbed in any way during the performance of his Works. If, any work is to be preformed which disturb such reference, the same shall be done only after these are transferred to other suitable locations under the direction of the Employer. The Contractor shall provide provide all necessary materials and assistance for such relocation of reference points etc. 37.0 WORK & SAFETY REGULATIONS 37.1 The Contractor shall ensure proper safety of all the workmen, materials, plant and equipments belonging to him or to Employer or to others, working at the Site. The Contractor shall also be responsible for provision of all safety notices and safety equipment required both by the relevant legislation and the Employer as he may deem necessary. 37.2 All equipment used in construction and erection by Contractor shall meet Indian/International Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe. All equipments shall be strictly operated and maintained by the Contractor in accordance with th manufacturer’s operation Manual and safety instructions and as per Guidelines/Rules of Employer in this regard. 37.3 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall be carried-out out in accordance with the relevant relevant provisions of Factories Act 1948, Indian Electricity Act 1910 and associated Laws/Rules in force from time to time. A register of such examinations and tests shall be properly maintained by the Contractor and will be promptly produced as and when desired by Employer or by the person authorised by him. Technical Specification:Sec-8l
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37.4 The Contractor shall provide suitable safety equipment of prescribed standard to all employees and workmen according to the need, as may be directed by Employer who will also have right to examine these these safety equipments to determine their suitability, reliability, acceptability and adaptability. 37.5 The Contractor shall provide safe working conditions to all workmen and employees at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc. The scaffoldings shall be erected under the control and supervision of an experienced and competent person. For erection, good and standard quality of material only shall be used by the Contractor. 37.6 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical equipment belonging to the Employer or other Contractors under any circumstances, whatsoever, unless expressly permitted in writing by the Employer to handle such fuses, wiring or electrical equipment. equipment 37.7 No electric cable in use by the Contractor/Employer will be disturbed without prior permission. No weight of any description will be imposed on any cable and no ladder or similar equipment will rest against or attached to it. 37.8 The Contractors shall employ necessary number of qualified, full time Electricians/ Electrical Supervisors to maintain his temporary electrical installations. 37.9 In case any accident occurs during the construction/ erection or other associated activities undertaken by the Contractor thereby causing any minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the Employer in prescribed form and also to all the authorities authoritie envisaged under the applicable laws. 37.10 The Employer shall have the right at his sole discretion to stop the work, if in his opinion the work is being carried out in such a way that it may cause accidents and endanger the safety of the persons and/or property, and/or equipments. In such cases, the Contractor shall be informed in writing about the nature of hazards and possible injury/accident and he shall comply to remove shortcomings promptly. The Contractor after stopping the specific work can, if felt elt necessary appeal against the order of stoppage of work to the Employer within 3 days of such stoppage of work and decision of the Employer in this respect shall be conclusive and binding on the Contractor. for any damages/ compensation for stoppage of work due 37.11 The Contractor shall not be entitled for to safety reasons as provided above and the period of such stoppage of work will not be taken as an extension of time for completion of the facilities. 38.0 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES
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38.1 The surfaces of foundations shall be dressed to bring the top surface of the foundations to the required level, prior to placement of equipment/equipment bases on the foundations. 38.2 All the equipment/ equipment bases, shall be grouted and finished as per these specifications unless otherwise recommended by the equipment manufacturer. 38.3 The concrete foundation surfaces shall be properly prepared by chipping, grinding as required to bring the top of such foundation to to the required level, to provide the necessary roughness for bondage and to assure enough bearing strength. 38.4 Grout The grout shall be high strength grout having a minimum characteristic compressive strength of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based, free flowing, nonnon metallic grout. The Grout shall have good flowability even at very low water/ grout powder ratio. The Grout shall have characteristics of controlled expansion to be able to occupy its original volume to filll the voids and to compensate for shrinkage. Grout shall be of pre-mix pre variety so that only water needs to be added before use. The mixing of the Grout shall conform to the recommendations of the manufacturer of the Grout. t Grout 38.5 Finishing of the Edges of the The poured grout should be allowed to stand undisturbed until it is well set. Immediately thereafter, the dam shall be removed and grout which extends beyond the edges of the structural or equipment base plates shall be cut off, flushed and removed. removed. The edges of the grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with the body of the grout and smoothened with a tool to present a smooth vertical surface. The work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed edges of the foundations, and structural steel and equipment base plates shall be thoroughly cleaned of any spillage of the grout. 38.6 CHECKING OF EQUIPMENT AFTER GROUTING After the grout is set and cured, the Contractor Contractor shall check and verify the alignment of equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as applicable and the like items to ensure that hat no displacement had taken place during grouting. The values recorded prior to grouting shall be used during such post grouting checkcheck up and verifications. Such pre and post grout records of alignment details shall be maintained by the Contractor in a manner acceptable to the Employer. 39.0 SHAFT ALIGNMENTS All the shafts of rotating equipment shall be properly aligned to those of the matching equipments to as perfect an accuracy as practicable. The equipment shall be free from excessive vibration so as to avoid overheating of bearings or other conditions which may tend to shorten the life of the equipment. The vibration level of rotating equipments measured at Technical Specification:Sec-8l
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bearing housing shall not exceed forty (40) microns and shall conform to VDI 2056.All bearings, gs, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting. 40.0 DOWELLING All the motors and other equipment shall be suitably doweled after alignment of shafts with tapered machined dowels as per the direction directi of the Employer. 41.0 CHECK OUT OF CONTROL SYSTEMS After completion of wiring, cabling furnished under separate specification and laid and terminated by the Employer, the Contractor shall check out the operation of all control systems for the equipment equipment furnished and installed under these specifications and documents. 42.0 COMMISSIONING SPARES 42.1 It will be the responsibility of the Contractor to provide all commissioning spares including consumable spares required for initial operation till the Completion of Facilities. The Contractor shall furnish a list of all commissioning spares within 60 days from the date of Notification of Award and such list shall be reviewed by the Employer and mutually agreed to. However. such review and agreement will not absolve the Contractor of his responsibilities to supply all commissioning spares so that initial operation operation do not suffer for want of commissioning spares. All commissioning spares shall be deemed to be included in the scope of the Contract at no extra cost to the Employer. 42.2 These spare will be received and stored by the Contractor atleast 3 months prior to the schedule date of commencement of initial operation of the respective equipment and utilised as and when required. The unutilised spares and replaced parts, if any, at the end of successful completion of guarantee tests shall be the property of the Contractor and he will be allowed to take these parts back at his own cost with the permission of Employer. Employer will be informed of the list of commissioning spares brought to site by the contractor before bringing the same to the site. 43.0 CABLING 43.1 All cables shall be supported by conduits or cable tray run in air or in cable channels. These shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right angle turn made of symmetrical bends or fittings. When cables cables are run on cable trays, they shall be clamped at a minimum intervals of 2000mm or otherwise as directed by the Employer. 43.2 Each cable, whether power or control, shall be provided with a metallic or plastic tag of an approved type, bearing a cable reference number indicated in the cable and conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at both ends of the Technical Specification:Sec-8l
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cable adjacent to the terminations. Cable routing is to be done in such a way that cables are accessible forr any maintenance and for easy identification. 43.3 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the cable. Installation of other cables like high igh voltage, coaxial, screened, compensating, mineral insulated shall be in accordance with the cable manufacturer’s recommendations. 43.4 In each cable run some extra length shall be kept at a suitable point to enable one or two straight through joints to be made, should the cable develop fault at a later date. 43.5 Control cable terminations shall be made in accordance with wiring diagrams, using identifying codes subject to the Employer’s approval. Multicore control cable jackets shall be removed as required equired to train and terminate the conductors. The cable jacket shall be left on the cable, as far as possible, to the point of the first conductor branch. The insulated conductors from which the jacket is removed shall be neatly twined in bundles and terminated. inated. The bundles shall be firmly but not tightly tied utilizing plastic or nylon ties or specifically treated fungus protected cord made for this purpose. Control cable conductor insulation shall be securely and evenly cut. rol cables shall be covered with a transparent insulating sleeve so as to 43.6 The connectors for control prevent accidental contact with ground or adjacent terminals and shall preferably terminate in Elmex terminals and washers. The insulating sleeve shall be fire resistant and shall be long enough to over pass the conductor insulation. All control cables shall be fanned out and connection made to terminal blocks and test equipment for proper operation before cables are corded together. 44.0 EQUIPMENT DELIVERY AND ERECTION 44.1 General Requirements (a.) This part covers Contractor's responsibilities for packing, shipping, warehousing and the installation of all equipment and materials furnished and installed under this specification. (b.) The Contractor shall submit for Employer's approval draft manual for Equipment Delivery and Erection covering detailed instructions, write up, technical data, drawings, check-lists, check documentation formats for all activities after equipment manufacture upto installation of equipment. This manual shall cover general general instructions for all equipment and specific instructions for individual equipment wherever required and shall include at least the following : ware housing and storage. i. Instructions for packing, shipping, receiving handling, ware-housing ii. Instructions for location and and installation of equipment furnished by this specification. iii. Installation drawings for field mounted equipment, panels, cubicles and other equipment covered under this specification. iv. Instruction relating installation of piping/ tubing, support and routing drawings of impulse pipes/signal tubes and tube/cable trays. Technical Specification:Sec-8l
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v. Check lists and quality assurance hold points. vi. Format for all related documentation. (c.) The Manual shall conform to the requirements of this specification, all applicable codes and standards, recommendations mendations of equipment manufacturers and accepted good engineering practices and shall be subject to Employer approval during detailed engineering. (d.) The Contractor shall ensure that all work under this part shall be performed as per the requirements of this is specification, Employer approved Manual and drawing/documents approved by the Employer during detailed engineering stage of work. 44.2 Crating (a) All equipment and materials shall be suitably coated, wrapped, or covered and boxed or crated for moist humid tropical shipment and to prevent damage or deterioration during handling and storage at the site. (b) Equipment shall be packed with suitable desiccants, sealed in water proof vapour-proof vapour wrapping and packed in lumber of plywood enclosures, suitably braced, tied and skidded. Lumber enclosures shall be solid, not slatted. (c) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to provide the required surface area and activated prior to placing in the packaging. Calcium sulphate desiccantss shall be of a chemical nature to absorb moisture. In any case, the desiccant shall not be of a type that will absorb enough moisture to go into solution. Desiccants shall be packed in porous containers, strong enough to withstand handling encountered during dur normal shipment. Enough desiccant shall be used for the volumes enclosed in wrapping. (d) Review by the Employer of the Contractor's proposed packaging methods shall not relieve the Contractor of responsibility for damage or deterioration to the equipment and materials specified. (e) All accessory items shall be shipped with the equipment. ; Boxes and crates containing accessory items shall be marked so that they are identified with the main equipment. The contents of each box and crates shall be indicated by markings markings on the exterior. (f) All boxes, crates, cases bundles, loose pieces, etc. shall be marked consecutively from No.1 upward throughout all shipments from a given port to completion of the order without repeating the same number. (g) An itemized list of contents shall be enclosed inside each case and one other copy securely fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket. The lists shall be plainly marked and placed in accessible locations to facilitate receipt and inspection. The packing list shall indicate whether shipment is partial or complete and shall incorporate the following information on each container, etc., according to its individual shipping number : 1. Export case markings 2. Case number 3. Gross weight eight and net weight in Kilograms 4. Dimensions in centimeters 5. Complete description of material
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(h) Packaging or shipping units shall be designed within the limitations of unloading facilities and the equipment which will be used for transport. Complications Complications involved with ocean shipment and the limitations of ports, railways and roads shall be considered. It shall be the Contractor's responsibility to investigate these limitations and to provide suitable packaging to permit safe handling during transit and at the job site. (i) Electrical equipment, control and instrumentation shall be protected against moisture and water damage. All external gasket surfaces and flange faces, couplings, motor pump shafts, bearing and like items shall be thoroughly cleaned and coated coated with rust preventive compound as specified above and protected with suitable wood, metal or other substantial type covering to ensure their full protection. (j) Equipment having antifriction or sleeve bearings shall be protected by weather tight enclosures. (k) Coated surfaces shall be protected against impact, abrasion, discolouration and other damage. Surfaces which are damaged shall be repaired. (l) All exposed threaded parts shall be greased and protected with metallic or other substantial type protectors. All female threaded openings shall be closed with forged steel plugs. All pipings, tubing, and conduit equipment and other equipment openings shall be sealed with metallic or other rough usage covers and tapped to seal the interior of the equipment piping, tubing, ing, or conduit. (m) Provisions shall be made to ensure that water does not enter any equipment during shipment or in storage at the plant site. (n) Returnable containers and special shipping devices shall be returned by the manufacturer's field representative at the Contractor's expense. (o) While packaging the material, care shall be taken for the limitation from the point of view of availability of railway wagon sizes in India. 44.3 Equipment Installation (a.)
General Requirements
The Contractor shall furnish all construction materials, tools and equipment and shall perform all work required for complete installation of all control and instrument equipment furnished under this specification. Contractor shall prepare detailed installation installation drawings for each equipment furnished under this specification for Employer's approval. Installation of all equipment/systems furnished by this specification shall be as per Employer's approval. Erection procedures not specified herein shall be in accordance accordance with the recommendations of the equipment manufacturers. The procedures shall be acceptable to the Employer. The Contractor shall coordinate his work with other suppliers where their instruments and devices are to be installed under specifications. specifications (b.) Installation Materials All materials required for installation, testing and commissioning of the equipment shall be furnished by the Contractor. (c.) Regulatory Requirements
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All installation procedures shall confirm with the accepted good engineering practice practi and with all applicable governmental laws, regulations and codes. (d.) Cleaning All equipment shall be cleaned of all sand, dirt and other foreign materials immediately after removal from storage and before the equipment is brought to installation site. (e.) Equipment Assembly Equipment installed under these specifications shall be assembled if shipped unassembled. The equipment shall be dismantled and reassembled as required to perform the installation and commi ssioning work described in these specifications. specifications (f.) Defects All defects in erection shall be corrected to the satisfaction of the Employer and the Project Manager. The dismantling and reassembly of Contractor furnished equipment to remove defective parts, replace parts, or make adjustments shall be included included as a part of the work under these specifications. The removal of control and instrument equipment in order to allow bench calibration, if required, and the re-installation re installation of the said equipment after calibration shall also be included as a part of the work under these specifications. 45.0 DEVIATIONS DISPOSITIONING: Any deviation to the contract and employer approved documents shall be properly recorded in the format prescribed by NALCO. Al the deviations shall be bought to the knowledge of employer’s representative for suitable dispositioning. DESTRUCTIVE TESTING ( NDT): 46.0 NON-DESTRUCTIVE The contractor shall record results of NDTs carried out at site in the format acceptable to employer. All the radiographs & its report duly signed & correlated to the job shall sh be handed over to the employer. Sensitivity of all the test equipment shall be compatible to the job & acceptance norms agreed. 47.0 TESTING EQUIPMENT & FACILITIES: Contractor shall provide the testing equipment and facilities necessary to carry out tests & inspections.
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SECTION 9 (MISCELLANEOUS) PAINTING 1.0 1.1
GENERAL This specification covers the materials, tools, facilities and quality requirement for surface preparation and painting of steel structures, equipment, piping including supports, hangers, gas and air ducts including hangers, chutes etc. g" referred herein covers rust preventive, preventive and decorative coating The term "painting" along with surface protection.
1.2
Surfaces in direct bonded contact with concrete, aluminium, asbestos, brass; bronze, galvanized steel, stainless steel, cast iron and other corrosion corrosion resistant alloys, rubber/synthetic polymers are not required to be painted unless specified except for aesthetic purposes or for identification bands. Except for such surfaces, painting and surface preparation shall be provided to protect all surfaces surfaces that shall be subjected to atmospheric action and exposed to corrosive medium. All machined mating surfaces (eg. flanges) shall be properly cleaned, greased and protected before dispatch.
1.3
The complete paint system for any item includes the following fo activities: i) Proper surface preparation ii) Application of primer coats iii) Application of intermediate coats iv) Application of finished coats All the above coats shall be of quality paint products and of approved make as stipulated in this specification. The he work shall also include supply of all paint materials as per specification described herein and of approved quality.
2.0
SURFACE PREPARATION
2.1
Surface preparation being a pre requisite for any paint application, shall be such as to clean the surface ace thoroughly of any materials which will be conducive to premature failure of the paint substrates. All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale, oil, grease, welding flux, etc. irrespective of whether the same has been spelt out in the standards in order that the prime coat is rigidly anchored to the virgin metal surface. The surface preparation shall conform to pictorial representation of surface quality grade of DIN
2.2
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55928 (Part 4) or BS 4232 or IS 1477 - 1971 ( Part I ). Any grease, oil, dust or foreign matter deposited on the surface after preparation preparation shall be removed and care taken that the surface is not contaminated with acids, alkalis moisture or other corrosive chemicals. The prime coat shall be applied as soon as possible after the surface preparation is completed. 2.3
The acceptable surfacee preparation quality / grades are described under each painting system. The procedures covered are solvent cleaning, hand tool cleaning, power tool cleaning and blast cleaning.
2.4
Solvent cleaning The surface shall be cleaned by wiping, immersion, spraying spraying or vapor contacting of a suitable solvent or washing with an emulsion or alkaline solution to remove oil, grease, dirt, old paint, etc. Solvent cleaning shall not remove rust, scales, mill scales or weld flux. Therefore, before application of paint,, solvent cleaning shall be followed by other cleaning procedures as stated elsewhere.
2.5
Hand tool cleaning The surface shall be cleaned by vigorous wire brushing done manually to St-2 St quality. This method effectively removes loosely adherent materials, materials, but would not affect residues of rust or mill scales that are intact and firmly adherent.
2.6
Power tool cleaning Electric or pneumatic tools shall clean the surface to St - 3 quality. The tools shall be used carefully to prevent excessive roughing roughing of surface and formation of ridges and burns. This method will remove loosely adherent materials but would not affect residues of rust or mill scales that are firmly adherent.
2.7
Blast cleaning
3.0
The surface shall be cleaned by impingement of abrasive abrasive materials, such as graded sand at high velocity created by clean and dry compressed air blast. This method will remove loosely adherent materials as well as adherent scales and mill scales. Prior to application of blast, heavy deposit of oil and grease are removed by solvent cleaning and excessive surface scales are removed by hand tools or power tool cleaning. The surface shall be cleaned to Sa - 2 1/2 quality i.e. 95 % of surface area is free from all rust, mill scales and visible residues, foreign materials, erials, etc. The blast cleaning is not recommended for sheet metal work. PRIMER PAINTS (P) Primer paints shall be applied only on dry and clean surfaces. 3.1 Primer paint P1 - (Phenolic - Alkyd based)
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A single pack air drying phenolic modified alkyd composition with zinc phosphate as a primer paint. Air drying time - About 60 minutes (touch dry) -Overnight (hard dry) Dry film thickness - 40 microns (min) (DFT / Coat)
4.0
3.2
Primer paint P2 - (Epoxy based) A two pack air drying Epoxy polyamide with zinc dust of at least 92 % zinc dust on the dry film. Epoxy content (% wt.) - 8 to 10 Air drying time - 10 minutes (touch dry) - 2 hours (hard dry) DFT / coat - 40 microns (min)
3.3
Primer paint P3 - (Ethyl zinc silicate, EZS, based) A two pack heavy duty zinc dust rich silicate primer which protects the surface with just a single coat. Total solids ( % wt ) - 84 +/- 2 Density ( g / cc ) - 3.07 +/- 0.05 Air drying time - To top coat 16 hours DFT / coat - 60 microns
INTERMEDIATE PAINTS ( I ) These paints shall be applied over primer coats as an intermediate layer to provide weatherproof seal of primer coats.
4.1
1 (Phenolic alkyd based) Intermediate Paint I-1 A single pack high build phenolic based paint of synthetic micaceous iron oxide. Air drying time -4 to 6 hours (touch dry) -2 days (hard dry) DFT / coat -75 microns (min) Temperature resistance -upto 100 deg C dry heat Compatible with -Primer P1 4.2
Intermediate Paint I-2 I
pack air drying high build epoxy resin based paint with MIO. A two-pack Air drying time - 6 to 8 hours (touch dry) - 7 days (full cure) DFT / coat - 100 microns Compatible with - Primer P2
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5.0
FINISH PAINTS (F) Finish paint coats shall be applied over primer coats and intermediate coats after proper cleaning and touch up of primed coats.
5.1
Finish Paint F1 A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint suitably pigmented. -3 to 4 hours (touch dry) -24 24 hours (hard dry) Air drying time DFT / coat - 25 microns (min) Compatible with Intermediate I1 - Primer P1 Colour - generally all shades
5.2
Finish Paint F2 A two pack air drying epoxy polyamide enamel suitably pigmented. Air drying time - 2 to 3 hours (touch dry) - 7 days (full cure) DFT / coat - 40 microns (min) Compatible with Intermediate I2 - Primer P2 Colour - generally all shades
5.3
Finish Paint F3 A single pack heat resistant silicon resin based paint with leafing Aluminium powder. Air drying time - 3 to 4 hours (touch dry)/24 hrs (hard dry) DFT / coat - 20 microns (min) Compatible with - no primer paint except P3 (shalll be applied on blast cleaned steel surface) Colour - smooth aluminium
6.0
PAINT APPLICATION
6.1
Paint shall be applied in accordance with paint manufacturer's recommendations. Manufacture of paints, mixing of paints, etc. shall be as per the IS codes of practice. The work shall generally follow IS 1477 -1971 1971 (Part II) for jobs carried out in India and or DIN 55928 (latest) or equivalent for jobs carried out outside India.
6.2
Paint shall not be applied when the ambient temperature is 500 C and d above or 450 C and below.. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and above unless the manufacturer's recommendations permit. Application of paint shall be only by spraying or brushing as per IS 486 - 1983 and IS 487 - 1985.
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6.3
Each coat of paint shall be continuous, free of pores and of even film thickness without thin spots.
6.4
Each coat of paint shall be dry sufficiently before application of next coat.
6.5
The colour code to be followed during painting shall be intimated to the successful Tenderer during finalization of order.
6.6
In the event of conflict between this general procedure for painting and the paint manufacturer's specification, the same shall shall be immediately brought to the notice of the Purchaser. Generally in cases of such conflicts, manufacturer's specifications / recommendations shall prevail.
6.7
General compatibility between primer and finishing paints shall be certified by the paint manufacturer anufacturer supplying the paints.
6.8
Areas that become inaccessible after assembly shall be painted before assembly (after painting clearance has been given by the inspecting authority) after requisite surface cleaning as specified. h cannot be painted but require protection shall be given a coat of rust inhibitive Surfaces which grease according to IS 958 - 1975 or solvent deposited compound according to IS 1153 - 1975 or IS 1674 - 1960.
6.9
6.10 Parts of steel structures embedded in concrete shall be given a protective coat of Portland cement slurry immediately after fabrication and after surfaces of this part is thoroughly cleaned from grease, rust, mill scales, etc. No paint shall be applied on this part. shade of the paint shall have the approval of the Purchaser. 6.11 The proposed make, quality and shade 6.12 Zinc rich primer paints which have been exposed several months before finishing coat is applied shall be washed down thoroughly to remove soluble zinc salt deposits. 6.13 The machine finished hed surfaces shall be coated with white lead and tallow before shipment or before being put out into the open air. 6.14 Total DFT for heat resistant paints should not exceed 100 -120 120 microns, otherwise flaking occurs ( as per paint manufacturer's recommendations recomme ). 6.15 Heat resistant paints should be applied by brush. 7.0
PAINTING SCHEME
7.1
For a complete painting scheme of any item being painted, all types of paints are to be procured from the same manufacturer as approved by the Purchaser.
7.2
Legend
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SP Surface preparation quality 2P1 Two (2) coats of primer paint type P1 1I1 One ( 1 ) coat of intermediate paint type I1 2F1 - Two ( 2 ) coats of finish paint type F1 DFT Dry film thickness Type of paint products like P1, P2, P3, I1, I2, F1, F2 and F3 have been specified under sl. nos.03, 04 and 05 of this specification. 7.3
The painting scheme to be followed for various equipment/ structures is briefly given below for guidance to the Tenderer. Painting scheme Sl. No. Description DFT Total At shop At site SP - St 3 1. Steel structure 2P1+1I1 2F1 100
2.
3.
Mechanical SP - Sa 2 1/2 (or St 3) equipment(temp. not over 80 deg C) Both static and 2P1+1I1 2F1 & 2F2 rotary equipment or 2P2+1I2 for indoor or outdoor duty Equipment with hot surfaces SP- Sa 2 1/2 (temp. 200 deg C and above) P3
2F3
205 (260)
100
8.0
Colour code For painting certain standard colour as listed below, shall be used by the bidder.
8.1
For electrical equipment
DESCRIPTION
COLOUR
11 kV, AC machine 3.3 kV, AC machine 400 V, AC machine 460 V, DC machine 250 V, DC machine 230 V, AC equipment 110 V, AC equipment All indoor control and switchgear panels
Light grey Post office red Brilliant green Azure blue Oriental blue Light orange Canary yellow Grey
Technical Specification:Sec-9,Miscellaneous
SHADE IS:5 631 538 221 104 174 557 309 697
AS
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All outdoor transformers, switchgear, control Dark admiralty 632 panel etc. grey Instrumentation panels Opaline green 275 Telecommunication panels Smoke grey 692 8.2
For mechanical equipment -Indoor Indoor and outdoor mechanical equipment excepting cranes : Grey.
8.3
For pipes, ducts, conduits and others Service River water (untreated) Cooling Water Boiler feed water Condensate
Drinking water
Industrial water Hydraulic power water Compressed air Instrument air Vacuum
Steam below 3.5 kg/cm2 (g)
3.5-20 kg/cm2 (g)
21-40 kg/cm2 (g) Above 40 kg/cm2 (g) Drainage Lubricating oil Hydraulic oil
Technical Specification:Sec-9,Miscellaneous
Colour Base - Sea green Band - White Base - Sea green Band - French blue Base - Sea green Base - Sea green Band - Light brown Base - Sea green First band - French blue Second band - Signal red Base - Sea green Band - Light orange Base - Sea green Band - Black Base - Sky blue Base - Sky blue Band - Light brown Base - Sky blue Band - Black Base - Silver grey if Bitulac or AlAl jacket Band - Brilliant green Base - Silver grey if Bitulac or AlAl jacket Band - French blue Base - Al-jacket Band - Dark violet Base - Al-jacket Band - Signal red Base - Black Base - Light brown Band - Light grey Base- Light brown
Shade as IS:5 217 217 166 217 217 410 217 166 537 217 557 217 101 101 410 101 628 221 628 166 796 537 410 631 410
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Transformer oil Fuel oil Coke oven/coal gas/other fuel gases Freon (chlorofluore methane and ethane)
derivative
Argon Acetylene
LP gas
Nitrogen Oxygen Regenerated acid (dilute) (1)
Hydrochloric acid (conc.) (1)
Spent liquor
Wash liquor
Dilute acidic liquor
Hydrofluoric acid (conc.) (1) Acidic slurries Alkalis Non-acidic slurries Fire fighting system Rain water down pipes
Technical Specification:Sec-9,Miscellaneous
Band - Dark violet Base - Light brown Band - Light orange Base - Light brown Band - Signal red Base - Canary yellow Band - Signal red of Base - Canary yellow Band - Light grey Base - Canary yellow Band - French blue Base - Canary yellow Band - Dark violet Base - Canary yellow First band - Signal red Second band - Traffic green Base - Canary yellow Band - Black Base - Canary yellow Band - White Base - Dark violet Band - Light brown Band - Dark violet First band - Light brown Second band - Light brown Base - Dark violet First band - Light brown Second band - Light brown Base - Dark violet Band - Light grey Base - Dark violet First band - Light grey Second band - Brilliant green Base - Dark violet Band - Silver grey Base - Dark violet Band - White Base - Dark violet Band - Deep buff Base - Sea green Band - White Base - Signal red Base - Sea green Band - Sky blue
796 410 557 410 537 309 537 309 631 309 166 309 796 309 537 267 309 309 – 796 410 796 410 410 796 631 410 796 631 796 631 221 796 628 796 796 360 217 537 217 101
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Duct work Lighting conduits Instrument conduits Power conduits
Technical Specification:Sec-9,Miscellaneous
Base - Aluminium Base - Black Band- Yellow Base - Black Band - Red Base - Black
309 537 –
Page 9 of 55
LIST OF MANDATORY SPARES A. 1.0
MECHANICAL Belt Conveyor Sl.No.
QTY.
2. 3. 4. 5. 6.
DESCRIPTION Pulleys -Driving Pulley -Non-Driving Driving Pulley Idlers Input shaft assembly (only pinion & input shaft) 1st Reduction Gear Oil seal Coupling
7.
Hold back
1 no. each type
8.
Safety devices - Pull chord switches - Belt sway switches - Zero speed switches
5% of total quantity 5% of total quantity 5% of total quantity
1.
2.0
1 no. of each size & type 1 no. each type 1 no. each type 2 nos. each type 1 no. each type
Actuator operated flap gate SL. NO. 1. 2. 3. 4. 5. 6.
3.0
1 no. of each size & type.
DESCRIPTION Plummer box Self aligning ball bearing Gaskets Limit Switch Sealing Oil Seal
QTY. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set.
Side Arm Charger SL. NO. DESCRIPTION 1. Gear box spares (complete gear box assy., oil seal and bearing) 2. Carriage wheels a) Bearings b) Oil Seals c) Plummer block d) Carriage wheel fitted with shaft (without Plummer Block) 3. Coupling 4. Travel wheel assembly 5. Bearing 6. Motor including slip ring motor, Bearings and Oil seal
Technical Specification:Sec-9,Miscellaneous
QTY. 1 set. a)1 set. b) 2 sets c) 1 set d) 1set 1 set. 1 No. 1 set. 1 set.each of type and size
Page 10 of 55
7. 8. 9.
Brakes complete assembly with lining and springs 1 set. Couplings with complete assembly, pins, bushes, and 1 set. nuts Hydraulic power Pack with all accessories 1 set. Wagon Tippler and Accessories
3.0
SL. DESCRIPTION QTY. NO. 1. Speed Reducers (a)complete gear box assy., (b)oil seal and a)1 set. b) 4 sets (c) bearing) c) 2 set of each type and rating 2. Motor a) Motor including slip ring motor, b)Bearings c) Oil a)1 set. b) 1 sets seal c) 1 set of each type and rating 3. Brakes a) Complete assembly b) Linings and springs 1 set. of each type and rating 4. Couplings with complete assembly, pins, bushes, and nuts 1 set. each type and rating/sise 5. a) Thyristor /VVVF cards/ Modules a) 1 No. of each type. B) 2 b) Relays No. of each type and rating 6
5.0
(a) Hydraulic Pump with electric motor, coupling, valves (mounted on pump) etc: (b) Hydraulic Motor (c) Valves (d) O.P. Coolers (e) Filter Elements (f)Pressure Switch (g)Temperature Switch Bearings (not covered separately)
1 Set of each type and size
1 No. of each type and size 1 No. of each type and size 1 No. 10 Nos. of each type 1 No. of each type 1 No. of each type 7 1 Set of each type and size 8 Limit Switches 2 Nos. of each type. 9 Cylinder Manifold block with all valves mounted on it 1 Set 10 Hydraulic cylinder with piston 1 Set of each type and size 11 Seals of hydraulic cylinder and pumps etc. 2 Sets of each type 12 Hydraulic hoses 2 sets 13 Gear box total 1 set 14 Gear flexible coupling 1set 15 Rod end bearings with housing 1 set for all four clamps 16 Pressure Switches, Common manifold block complete with 1 no. each all valves mounted on it, Main Pivot bearing, 17 Pinion support & bearing 1 No each type 18 Pinion 2 nos 19 Latch (Pinion & rack segment locking device) 1 No. 20 Chain & Sprocket 1 set Apron Feeder
Technical Specification:Sec-9,Miscellaneous
Page 11 of 55
SL. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 14 15 16 17
6.0
QTY. 1 No. 1 No. 1 No. of each type and size 1 No. of each type and size & direction. 1 No. of each type and size 1 Set of each type and size 1 Set of each type and size 20% of population 20% of population 20% of population 2 Sets of each type and size 20% of each type and size 10% 1 set of each type and size 1 set 1 No. of each type and size 1 Set of each type and size
Electric Hoist SL. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
7.0
DESCRIPTION Head Pulley complete with shaft Tail pulley complete with shaft Drive Motor Gear Box Complete internals of gear box including input and output shafts Reduction gears Fluid coupling, flexible coupling etc. Traction rollers Carrying idlers Return Rollers Sprocket segments Link Chain Pans (flights) Hydraulic cylinder Seal kit of hydraulic cylinders Plummer blocks Bearings
DESCRIPTION Ball bearing Needle bearing with inner race Bush bearing Rope tightener Rope guide Rope sheave Thrust bearing Roller bearing with inner race Brake lining Limit switch complete Rotor pinion
QTY. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set.
DESCRIPTION Grooved sheave Pinion Bearing
QTY. 2 sets 1 set 1 set
Manual Hoist SL. NO. 1. 2. 3.
Technical Specification:Sec-9,Miscellaneous
Page 12 of 55
4. B.
Shaft pin
1 set
ELECTRICAL Sl. No. MCC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
DESCRIPTION
QUANTITY
14.
Busbar support insulators Current transformers Potential transformers 415/110V Male contact of ACB (main and aux.) Female contact of ACB (main and aux.) Limit switch of ACB Spring charging motor of ACB Closing coil of ACB Tripping coil of ACB Breaker control switch Relays Auxiliary relay Indicating Lamp assembly (LED LVGP type) Phase sequence meter
10 Nos. of each type / MCC 1No. of each type & rating / MCC 1 No. / MCC 1 set /MCC 1 set / MCC 3 Nos. /MCC 3 Nos. /MCC 2 Nos. /MCC 2 Nos. /MCC 2 Nos. /MCC 1No. of each type/ MCC 2 Nos. of each type / MCC 10 Nos. of each type & colour /MCC 2 Nos.
Sl. No. 1.
DESCRIPTION Lightning arrester
2.
Isolator with earth heel
3.
Relays
QUANTITY 1 set each at receiving and WT substation 1 set each at receiving and WT substation 1No. of each at receiving and WT substation
1. 2. 3. 4. 5. 6. 7.
Bearing (drive end) Bearing (Non-drive (Non end) End shield (DE and NDE) Cooling fan of motors Fan cover Bearing puller Grease gun
33 KV SYSTEMS
MOTORS
Technical Specification:Sec-9,Miscellaneous
1 No. of each type 1 No. of each type 1 set of each type 1 No. of each type 1 No. of each type 1 Nos. of each type 2 Nos.
Page 13 of 55
PDB/LDB/SLDB/AUX. PDB 1. 2. 3. 4. 5.
Bus bar support insulators MCCB MCB Breaker control switch Control switch
3 Nos. of each type / DB 2 Nos. of each rating/DB 2 Nos. of each rating/DB 2 Nos. /DB 2 Nos. of each type/DB
1. 2. 3. 4.
HV bushing (1 set = 3 nos.) LV bushing (1 set = 3 nos.) Temp. scanner Neutral bushing CT
1 set 1 set 1 no. 1 no. of each type/ ratio
1. 2. 3.
Thyristor fuse Electronic logic card for UPS Electronic logic card for PLC
1 no. of each rating 1 no. of each type 1 no. of each type
LT TRANSFORMER
UPS/PLC
CONTROL DESK/ AMMETER CONTROL PANEL 1. 2. 3. 4.
Ammeter Indicator Lamp Assembly Control switch Push button
1 No. of each range 5 sets 1 no. of each type 1 no. of each type
1. 2. 3. 4.
Lamps Fittings Control gear complete Timer
4 Nos. of each type 2 Sets of each type 2 Sets of each type 1 No.
ILLUMINATION
C.
VENTILATION, AIRCONDITIONING & DRY FOG DUST SUPPRESSION SYSTEM SYSTEM / EQUIPMENT DESCRIPTION Air Washing type Ventilation Systems. Centrifugal Fans & Filters V -Belt Bearings Flexible Connection Filter element Water Pump Impeller
Technical Specification:Sec-9,Miscellaneous
QUANTITY 1 set of each type 1 set of each type 1 set of each type 20% of requirement 1 set of each type
Page 14 of 55
Coupling 1 set of each type Bearings 1 set of each type 2 sets of each type Gland Packing Nozzles Nozzles 10% of requirement Valves Valves 1 set of each type Exhaust Fans Bearings 1 set of each type Dry Fog & Plain Water Sprinkling type Dust Suppression Systems Water Pump Impeller 1 set of each type Coupling 1 set of each type 1 set of each type Bearings 2 sets of each type Gland Packing Nozzles Nozzles 10% of requirement 20% Nozzle tips of requirement Sprinklers Nozzles 10% of requirement Solenoid Valves Solenoid Valves 10% of requirement Pressure gauges Pressure Gauges 1 set of each type Sensors and Instruments Sensors & Instruments 1 set of each type Valves Valves 1 set of each type Pressure Regulating Units PRU 1 set of each type (PRU) Flow Activation Station FAS 1 set of each type (FAS) Compressor Bearings 1 set of each type Couplings / V Belts 1 set of each type 1 set of each type Pulleys 1 set of each type Filters 1 set of each type Gaskets / O Rings 1 set of each type Valves /Safety valves 1 set of each type Piston rings
Technical Specification:Sec-9,Miscellaneous
Page 15 of 55
INFORMATIONS TO BE FURNISHED BY THE BIDDER Check List for Bid submission 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17 2.0
All drawings and documents duly signed as per TS submitted along with Bid Clause wise list of deviations from TS furnished Time bar chart and level of PERT network furnished as per the TS Separate price bid submitted Necessary particulars to establish the possession of technical knowknow how and facilities available furnished as per TS Reference list for supply of similar equipment along with users’ certificate furnished as per the TS Write up of testing facilities available at works furnished as per the TS Brief scope of collaboration for collaboration agreement furnished as per the TS Clause wise list of deviations / exclusions furnished as per the TS Delivery schedule indicated as per TS Bought out items conforms to TS Location and size of MCC & control room indicated List of tools furnished as per TS List of commissioning spares furnished as per TS List of spares for two years operation along with item wise price furnished as per TS List of insurance spares with price furnished as per TS Erection plans furnished as per TS
- Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No
Questionnaire The Bidder shall fill in this questionnaire and submit in hard as well as a soft copy with their Bid. This data shall form a part of the contract with successful Bidder.
2.1
General 1. 2. 3. 4. 5.
6.
Name and address of the Bidder Previous experience of the Bidder List of similar equipment supplied Whether the Bidder has any technical collaboration with any other company / organization for his equipment If answer to question 4.0 is yes, furnish the following details. a) Name and address of the collaborator b) Nature of the collaboration in detail c) Previous experience of the collaborator List of drawings literatures enclosed with the offer
Technical Specification:Sec-9,Miscellaneous
Page 16 of 55
7
Is it the Bidder's intention, if awarded the contract, to comply fully in all respects with owner’s specifications covering the work? If not, he shall state specific exception in details
A. WAGON TIPPLER GENARAL Type: Designed capacity Guaranteed capacity Make: Capacity: Angle of tipping: Drive: Tippler drive: Side arm charger: Indexer: Clamping: Wt. of the machine Tippling time cycle: Rail Gauge: Drive Rack Assembly Spherical roller bearing SKF NO.24168 ECACK30/W33/Equivalent. CLAMP CYLINDER Bore Rod Stroke Tippler Ballast-25T 25T at each end frame Made from concrete with steel scrap DRIVE PINION P.C.D Face width No.of teeth Pressure angle Material CYLINDER FOR INHAUL CLICKING STOP Bore Rod Stroke
Technical Specification:Sec-9,Miscellaneous
Page 17 of 55
HYD.POWER PACK DETAILS FOR WT Type Oil pump proportional control of capacity Tank capacity Electric motor for WT main drive Electric motor for WT clamp Cooling HYDRAULIC MOTOR DATA FOR WAGON TIPPLER Type Model Displacement Speed Details of Motor Pressure (Max) Torque theoritical Power theoritical (Max) Speed (Max) HYDRAULIC CYLINDER DATA FOR WAGON TIPPLER Bore Rod Stroke SIZE OF WAGON TO BE HANDLED Length Width Height B.
APRON FEEDER: GENERAL Make: Capacity: Pan width: Length: Motor DRIBBLE CONV. GENERAL Conv.Belt Belt width Belt length
Technical Specification:Sec-9,Miscellaneous
Page 18 of 55
C.
WEIGHBRIDGE GENERAL Make Quantity required Carrying capacity /strength Weighing capacity Type Platform size Mounting Resolution Taring facility Auto tare Purpose Cycle of weighment Duty Power supply required Operating temp.range Platform size Material of construction Load cell Load cell capacity
D.
SPECIFICATION OF LOAD CELL GENERAL Characterstic Make Type No.of loadcells Capacity of each loadcell Rated output Combined error Repeatability CREEP ON LOAD (30min) Zero balance voltage Input resistance Output resistance Compensated temp.range Operating temp.range Temp.effect on span Temp.effect on tare
Technical Specification:Sec-9,Miscellaneous
Specification
Page 19 of 55
Excitation voltage Safe overload Ultimate overload Insulation resistance Protection Cable E.
F.
CONTROLLER GENERAL CHARACTERISTIC Model no. Type Power supply Operating temperature Range Resolution Non - linearity Repeatability Excitaton to transducer Display Input Output Programmable parameters Casing dimension
SPECIFICATION
SIDE ARM CHARGER Type of side arm charger (sac) Sac pulling capacity SAC total travel Max.wagon size that sac can handle Type of luffing system for sac Track gauge Operating speed of sac in m/s Forward with single wagon Return Type of power supply system for sac Support roller wheel Guide roller wheel Feston support post Electric motor for sac Cooling DRIVE PINION P.C.D Face width
Technical Specification:Sec-9,Miscellaneous
Page 20 of 55
No.of teeth Pressure angle Material RACK FOR SAC TRAVEL Total nos Pitch Pressure angle Teeth per rack Material HYD.POWER PACK DETAILS FOR SAC TYPE Oil pump proportional control of capacity Tank capacity Electric motor for SAC Cooling HYD.MOTOR DETAILS FOR SAC Hyd.motor double displacement type Motor model: Displacement: Details of Motor Pressure (Max) Torque theoritical Power Speed (Max) SAC RAISE & LOWER CYLINDER Bore Rod Stroke SAC UNCOUPLING CYLINDER Bore Rod Stroke SAC DELATCH CYLINDER Bore Rod Stroke G.
INDEXER Type of side arm charger (sac) Max.rake (Train) size that Indexer can handle Type of luffing system for Indexer Track gauge
Technical Specification:Sec-9,Miscellaneous
Page 21 of 55
No.of wagon handled by Indexer Operating speed of Indexer in m/s Forward with rake Return Type of power supply system for Indexer Fixed support roller wheel Guide roller wheel Sprung support roller assembly Feston support post Indexer normal travel DRIVE PINION P.C.D Face width No.of teeth Pressure angle Material RACK FOR INDEXER TRAVEL Total nos Pitch Pressure angle Teeth per rack Material HYD.POWER PACK DETAILS FOR INDEXER TYPE Oil pump proportional control of capacity Electric motor for Indexer Cooling HYD.MOTOR DETAILS FOR INDEXER Hyd.motor double displacement type Motor model: Displacement: Details of Motor Wt Pressure (Max) Torque theoritical Power theoritical (Max) Speed (Max) INDEXER ARM RISER CYLINDER Bore Rod Stroke INDEXER UNCOUPLING CYLINDER
Technical Specification:Sec-9,Miscellaneous
Page 22 of 55
Bore Rod Stroke 2.2
BELT CONVEYORS Sl. No 1
2 3 4 5 6 7
8
9
10
11
Description Belt Conveyor System Conveyor capacity, Mt/h a) Rated (guaranteed) b) Design Belt width, mm Belt speed, m/sec Length, centre to centre, m Lift, m Max. angle of inclination, degree Radius of curvature for : a) Concave b) Convex Details of take-up i) Type of take-up a) For Boom conveyor of stacker / reclaimer b) For Intermediate Conveyor of stacker c) For all other conveyors Belting i) Type of fabric ii) Cover grade iii) Cover thickness, mm - Face cover, mm - Back cover, mm iv) No. of plies v) Troughing angle vi) Factor of safety vii) Normal working tension viii) Type of belt joint i) Idler type: a) Carrying (except in case of reversible conveyor) b) Return c) At loading point ii) Idler Spacing a) Carrying b) Return c) At loading point d) Self aligning (carrying side) e) Self aligning (return side) Pulleys : i) Minimum shell thickness ii) End disc thickness
Technical Specification:Sec-9,Miscellaneous
Page 23 of 55
12
13
14
15
16
17
18
19 20
21
22
23
iii) Shaft deflection at hub iv) Lagging thickness v) Lagging vi) Pulley Material (For ILMS conveyor) vii) Shaft material Drive Pulleys i) Lagging ii) Diamond pattern groove iii) Minimum angle of wrap iv) Maxm. out of roundness Rubber for pulley lagging i) Type ii) Shore Hardness iii) Elongation iv) Strength v) Abrasion loss vi) Specific gravity vii) Adhesion Strength Emergency Stop Switch & Belt Sway Switch System i) Spacing (Emergency stop) ii) Spacing (Belt Sway Switch) iii) Degree of protection Zero Speed Switch i) Type ii) Mounting location Conveyor Gallery a) Walkways width b) Side windows in staggered fashion i) Spacing (c/c) ii) Size Deck plates a) Material b) Thickness, mm Seal plates a) Material b) Thickness Stone picking arrangement Chute Jamming Detector (a) Type (b) Degree of Protection Reduction gears a) Type b) Size Fluid Couplings a) Type b) Rating, kW Brakes
Technical Specification:Sec-9,Miscellaneous
Page 24 of 55
a) Type b) Rating c) Protection Flexible couplings a) Type b) Rating Drive motors a) Type b) Make c) Insulation class d) Motor nameplate rating, kW at 500 C ambient e) Protection Class
24
25
2.3
CHUTES, HOPPERS,SKIRT BOARD Sl. No 1 2 3
4
2.4
Description Chutes & hoppers construction Minimum valley angle (from the horizontal), degree Material & Plate thickness a) Sliding zones and adjacent sides b) Non striking/ non sliding zones c) Chute with valley angle 80° and above d) In the zone of magnetic field of ILMS e) In the zone of flap gates f) Discharge Hoods over head pulleys g) Location of Inspection door/sealing Skirt board a) Plate thickness, mm b) Length of each skirt board, m c) Height, mm d) Width, mm e) Top cover plate thickness , mm
ACTUACTOR OPERATED FLAP GATE Sl. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Description Make Dimensions Material of construction of the gate Liner plate specification Method of fixing of liner plates Type and make of drive and rating Capacity and designation of the equipment Total weight and weight of individual parts Type of actuator and thrust in kg of each actuator Stroke in mm of each actuator Velocity mm per of each actuator Motor: Type, rating, power supply, class of duty, insulation, make number of starts/ hours
Technical Specification:Sec-9,Miscellaneous
Page 25 of 55
13. 14 15.
2.5
Make, ratings, type of limit switches Effort required for manual operator, kgf Type of limit switches
ELECTRIC HOISTS Sl. No 1. 2. 3. 4. 5. 6. 7.
8.
9.
10.
11.
12.
13. 14. 15. 16.
17. 18. 19.
Description Location Capacity Duty classification as per IS:3938-1983 IS:3938 Total weight of hoist including electrical equipment Make of hoist block Speeds with safe working load Lifting height a) Above floor level b) Below floor level Wire ropes a) Type of construction b) Size c) Number of falls d) Factor of safety Rope drum a) Materials b) Diameter Drives a) Type & material of gear box b) Gear & pinion c) Material & hardness Motors a) Type & number b) Kw rating c) Synchronous speed d) Class of insulation e) Pull out torque f) Frame size Brakes a) Type b) size c) Torque rating Type & details of limit switches Type of couplings Type of bearings Lifting hook a) Type b) Material Type & details of control Trolley Speed with safe working load Wheels
Technical Specification:Sec-9,Miscellaneous
Page 26 of 55
20.
21
22. 23. 24. 25. 26. 27. 28. 29. 30.
2.6
a) Numbers b) Diameter c) Material & hardness d) Max. wheel load e) Wheel base Drive a) Type & material of gear box b) Gears & pinions c) Material & hardness d) Kw rating e) Synchronous speed f) Class of insulation g) Pull out torque h) Frame size Brakes a) Type b) Size c) Torque rating Type & details of limit switches Type of coupling Type of bearings Type & details of controls Clearance diagram indicating the basic dimensions Type & lubrication provided Type & size of cables Location & control details of hoist block power feeding Any other information
EOT CRANE Sl. No.
Description
(a)
During participation in technical Bid:
1.0 2.0 3.0
G.A. Drawing. VENDER TO CONFIRM Wheel Load Diagram (Wheel Distance & Wheel Load). Sketches showing full details of cranes with dimensions/ end clearances (between centre of LT rails to column face of building), overhead clearance from LT rails, hook approach limits, lift lift height, Details of Web thickness baffle plates, Stiffeners ,of Girder section , End carriage (Boggies) Trolley Section etc. Vendor to submit appropriate Q.A. Plan.
4.0 (b) 1.0
After Receipt of Order: Calculation for Box Girder, End Carriage structural plates/ Web / Stiffener plate, Wheel Load calculation & Calculation for selection of Diameter of Wheel, Motor, Gearbox and Brake etc. 3 - sets of followings documents like G. A Drawings, Structural drawings drawin like End-carriage, carriage, Box Girder, Assembly Drawings/ Sub-- assembly Drawings, Gear Box Drawings (specially of Typical Gears having Helix Angle, Pressure Angles, Modules etc.) ,Bracket/ Current Collector System, Hook Block, LT & CT wheel, Main Hook assembly LT machinery, Hoisting machinery, Electrical Drawings comprising Power ,
Technical Specification:Sec-9,Miscellaneous
Page 27 of 55
(c) 1.0 2.0 3.0 4.0 5.0 6.0
2.7
MANUAL HOISTS Sl. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 11. 12. 13.
3.0
Control Circuits , Electronic Circuitry diagram for RRC etc. No fabrication / purchase of BO. Items should be taken up before the approval of the drawings. With the supply of crane: c Operating manuals of Crane - 3 Sets. Detailed Maintenance manual of Crane. SparesSpares part list / concerned drawing of the spares -3 3 Sets. Maintenance, Interface & commissioning manuals for Controller & drives - 2 Sets along with drive parameterisation software. Catalogues, O&M Manuals of all bought out items including drawings, wherever applicable. Detailed specification of all rubber items like OilOil Seals / O- Rings etc. One Soft copy for the above requisites shall also be supplied in CD.
Description Name of the manufacturer, type & model no Numbers offered & their location Safe working load for each hoist (in tones) Duty class as per IS:3832-1983 IS:3832 Head room, mm Lift, mm Minimum radius of curvature of which this hoist can negotiate (mm) Weight of each hoist Specification of each chain Tools & tackles included in offer Commissioning spares & 2 years Operating spares included in offer Any other information
DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE BIDDER Drawings /Data along with the Bid 1) Schematic drawings showing flow of materials. 2) Layout drawings of Additional Coal Storage and Handling System showing clearly the Major Equipment, Junction Houses, Conveyor Galleries, Approach Road, Rail Track for Yard Equipment, Yard Drainage Scheme etc. 3) General Arrangement Drawing of Additional Coal Storage and Handling System showing clearly the Major Equipment, Junction Houses, Conveyor Galleries, Belt Conveyor with drive, tail and take up arrangement, hoisting & handling facilities envisaged for maintenance of equipment. tional Coal Storage Yard showing the coal stock pile, yard equipment, 4) Cross Section of Additional track rail for stacker and reclaimer, yard drainage system etc.
Technical Specification:Sec-9,Miscellaneous
Page 28 of 55
5) General Arrangement of Major Equipment showing plan, elevation, cross sections along with mounting details, with broad dimensions d and technical parameters. 6) Basic calculation substantiating selection of all major equipment, motors, gear boxes, couplings, brakes etc. 7) Equipment wise List of commissioning spares and consumables with item wise description and quantity included d in the main offer. 8) Equipment wise list of 2 years operational spares (un-priced). (un priced). The list shall indicate description and quantity for each item. 9) List of special tools and tackles 10) Details /drawings for Civil & Structural Engineering works. 11) Single line diagram of power distribution system. 12) Electrical schematic diagrams 13) Cable specifications, cables schedule and cable layout drawings. 14) Any other structural / mechanical / electrical etc. drawings / data mentioned elsewhere in the technical specification as well as considered necessary by the Purchaser/ Consultants. 15) List of exclusion, if any from Bidder’s Scope of Work. 16) List of deviations from technical specification. 4.0 4.1
ELECTRICS DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE TENDERER Drawings / Data / Documents along with the Bid 1.
Detailed scope of work with general description of the system & equipment offered specifying the important features and detailed design criteria and design philosophy including full details of reference data, assumptions, etc.
2.
Description to be accompanied by single line diagrams and equipment layout to enable owner to have proper appreciation of equipment offered and its operation.
3.
-priced) in specified format, with division list of supplies from foreign Bill of Quantities (un -priced) and indigenous sources.
4.
List of specific exclusions, if any, from Bidder’s Scope of Work.
5.
List of deviations from technical specifications,
Technical Specification:Sec-9,Miscellaneous
Page 29 of 55
6.
Equipment wise List of commissioning spares and consumables with item wise description and quantity included in the main offer.
7.
List of 2 years operation spares, equipment wise (un-priced). (un priced). The list shall indicate description and quantity for each item.
8.
List of special tools and tackles
9.
Work Schedule with bar chart indicating all activities for electrics.
wise construction power requirements for erection / testing activities. 10. Phase-wise filled 11. Questionnaire as asked, duly filled-in. 12. Reference list of similar jobs carried out 13. Dimensional details & weights of each equipment offered (tentative) Technical Data to be submitted with the Bid.
4.2
1.
Name and capacity of MCC considered
2.
List of LT drives of each MCC along with single line diagrams
3.
Connected load and Maximum demand of each section of 33 kV switchboard/ 415 V PCC
4.
Connected load and Maximum demand of each section of MCC.
5.
List of motors with ratings ( working+ working+ standby) 6. List of performance tests proposed by the tenderer to demonstrate the guaranteed parameters for the electrical equipments. 7. Specific energy consumption, maximum demand and annual energy consumption. 8. Type test certificates for major categories categories of equipment, issued by independent testing authority. 9. Technical catalogues of major equipment offered. 10. Services to be provided by owner at battery limit with specification 11. Single Line Diagram of each MCC/ DB 12. Capacity of UPS for stacker stacker & reclaimer 13. Capacity of PLC for stacker & reclaimer 14. Size of HT/LT trailing cables considered 15. Rating of 33 kV on load isolators considered
TECHNICAL PARTICULARS TO BE SUBMITTED BY THE BIDDER ALONG WITH THE BID GENERAL data asked under this section shall be furnished by the tenderer along with The information /data the offer. In the event of the contract being awarded , the data/technical particulars furnished here under and accepted by the owner shall be deemed to form a part of the contract. contract Design Considerations 1. List of Drives/ Mechanism with kW Rating
Technical Specification:Sec-9,Miscellaneous
: :
Page 30 of 55
2. Aux. Power Consumption
:
Spares and tools & tackles 1 .List of commissioning spares 2. List of mandatory spares 3. List of special tools and tackles
: List to be submitted : List to be submitted : List to be submitted
Summary Of Technical Parameters Of Major Electrical Equipment Sl. Equipment Make & type Total Dimension Rating as Guaranteed No. Description / Country of Weight per design Tech Data manufacture condition of & Qty Tender
MOTOR 1. Make, type & applicable standard 2. Furnish following for all drives Sl. No
Application
Working /Standby
Rated Parameters kW
Voltage
MCC 1. Make, Type & Applicable Standard 2. Rated Voltage, current & Frequency 3. Short time rating 4. Bus bar material & type of sleeving 5. Protection class Components of MCC 1 Air Circuit Breaker 2. MCCB 3. AC Contactor 4. DC Contractor 5. Thermal Relay 6. Control Devices 7. Meters
Technical Specification:Sec-9,Miscellaneous
Speed
Enclosure
Qty
: : : : : Make & Type : : : : : : :
Page 31 of 55
MCC WISE DATA Sl. MCC No Designation
Rating of Single Volt, Front/ Amps Double Front
No. of Connected Max. No. of Overall bus load per load d per panels dimensi section ons sections section
RELAYS 1. 2. 3. 4.
Make Type Draw out type with built in test facility Relay details
1. 2. 3. 4.
Make Type Reference standard Size
METERS
CURRENT TRANSFORMER 1. Make, type & applicable standard 2. Ratio & accuracy class: metering/protection 3. Rated voltage – short time rating POTENTIAL TRANSFORMER 1. 2. 3. 4. 5.
Type Primary/secondary voltage ratio Method of connection Rated voltage factor Class of insulation
PDB/LDB/SLDB/AUX. PDB (SEPARATELY FOR EACH DB) 1. 2. 3. 4. 5.
Make, Type & Applicable Standard Rated Voltage, current & Frequency Short time rating Bus bar material & type of sleeving Protection class
Technical Specification:Sec-9,Miscellaneous
Page 32 of 55
Components of DB 1. 2. 3. 4. 5. 6.
Breaker MCCB/MCB AC Contactor Thermal Relay Control Devices Meters
DB-WISE DATA Sl. No
DB Designation
Rating of Volt, Amps
Single No.of Front / bus Double sections Front
Connected Max. load per load per section section
No. of Overall panels dimensions
TRANSDUCER (For each type) 1. 2. 3. 4. 5. 6.
Make Output range Accuracy Maximum burden on CT/PT Nominal input/rated I/V Overload capacity without loss in accuracy
LIGHTNING PROTECTION 1. 2. 3. 4. 5. 6.
Whether lightning conductors have been envisaged for the lightning protection Angle of protection Whether building is also protected Number of electrodes provided Earthing resistance value Size of down conductors
: Places to be indicated : : Yes/No : : :
EARTHING 1. 2. 3.
Material and size of earth strip for the various places Size of main outer strip Galvanising content on GI strip
Technical Specification:Sec-9,Miscellaneous
: : :
Page 33 of 55
4. 5. 6.
Value of earthing resistance (proposed to be achieved) Type & size of electrodes Construction of earthing mat, etc as per TS
: : : Included
UPS SYSTEM 1. Make of the system 2. Capacity in kVA 3. Battery back up time 4. Make & type of battery 5. Number of cells per battery 6. Overall dimension(L x B x H) mm of battery 7. Ventilation requirements 8. Make, Rating & type of charger 9. Make, Rating & type of rectifier transformer 10. Make & current rating of SCR & Diode 11. Make & rating of inverter 12. Make & type of static transfer switch 13. Make & rating of manual bypass switch TRANSFORMER 1. Name of manufacturer 2. Service-whether whether indoor or outdoor 3. Type of cooling 4. Rating a. Rated KVA b. Rated current, amp (rms), HV/LV c. Rated voltage, kV (HV/LV) 5. Temperature rise above 500C ambient a. In oil by thermometer, 0C b. In winding by resistance, 0C c. Hot spot temperature in winding limited to, 0C 6. Insulation class 7. Vector group 8. Type of tap changer with capacity/steps/range 9. Tapping provided on HV side? 10. Losses load loss at rated voltage and frequency a. No-load b. Load loss at rated load c. Cooler loss 11. Impedance at rated current frequency 12. Reactance at rated current and frequency, % 13. Efficiency at 0.80 p.f lag % at 100%/75%/50% load 14. Load/p.f. at which max. efficiency occurs, % full load
Technical Specification:Sec-9,Miscellaneous
: : : : : : : : : : : : :
: : : : : : : : : : : : : Yes/No : : : : : : :
Page 34 of 55
15. Maximum efficiency, % : 16. Minimum clearances in mm HV LV a. Between phases : b. Between phase and ground : 17. Withstand time without injury for 3 ph short circuit, sec : 18. Insulation strength : a. one minute power frequency test KV rms b. Impulse withstand voltage, KV : 19. Tap changer provided with i. Tap position indicators ? : Yes/No ii. Operation counter ? : Yes/No iii. Padlocking provisions ? : Yes/No 20. Details of tank : i. Material ii. Maximum internal withstand pressure of tank kg/cm2: 21. Enclosure details (for dry type transformer) i. Material : ii. Thickness : iii. Degree of protection : 22. Details of core material : 23. Insulation material : 24. Details of bushings HV LV LV- Neutral a. Make : b. Type : c. Voltage class, KV : 25. Insulating oil a. Approx volume of oil, liter : b. Whether first filling of oil with 10% excess included ? : c. Oil conforms to IS:335 :335 ? : 26. Marshalling Box a. Weatherproof, suitable for outdoor for oil filled type ?: Yes/No b. Degree of protection : 27. Each transformer with fittings andaccessories : Yes/No 28. Approximate overall dimensions, (LxBxH) mm : 29. Approximate weights, Kg : a. Core and coil : b. Tank and fittings : c. Oil : d. Total weight : 30. List of special maintenance tools and accessories : Furnished Neutral CT of transformers (for each type) cable standard 1. Make, type & applicable 2. Ratio & accuracy class: metering/protection 3. Rated voltage – short time rating
Technical Specification:Sec-9,Miscellaneous
: : :
Page 35 of 55
LIGHTING MAST General 1. Make 2. Material of construction 3. Cross section of mast in polygon (No. of sides) 4. Thickness in mm (bottom/middle/top sections) 5. Length of individual sections (mm) 6. Base dia & top diameter (OAF) 7. Type of joints 8. Length of overlap (joint at site mast Section in mm): 9. Thickness of galvanization (minimum) 10. Size of opening door at base (mm) 11. Type of locking arrangement & door construction: 12. Weights in kgs of 30 mtrs high mast 13. Dynamic loading as prevailing actual at site 14. Maximum wind pressure (Basic wind speed) 15. Maximum gust speed ed time 16. Factor of safety for wind load 17. Factor of safety for other loads
: : : : : :
Lantern Carriage 1. Diameter of carriage ring (mm) 2. Load carrying capacity 3. Total weights of assembly with fittings 4. Number of fittings
: : : :
Winch 1. Make of winch, number of drums per winch 2. Capacity 3. Operating speed 4. Method of operation 5. Tested load per drum (kg) Wire Rope 1. Grade 2. Number of ropes/thickness 3. Construction 4. Breaking load capacity 5. Factor safety Cable 1. Type 2. Make 3. Current carrying capacity 4. Cable size
Technical Specification:Sec-9,Miscellaneous
: : : : : : : : :
: : : : : : : : : :
: : : :
Page 36 of 55
5.0
5.2
Power Supply arrangement 1. Input supply : 2. KW rating of motor : 3. Speed of motor : 4. Reversible / Non reversible : 5. Remote control switch type : 6. Lifting capacity of torque Limiter : Ventilation, Air Conditioning and Dust Suppression System. 5.1
Bidders shall furnish all information as stipulated in relevant chapter. Bidders shall also furnish the following information:
a)
Process flow, process instrumentation and control diagram and water and compressed air balance diagrams.
b)
Dimensioned general arrangement and relevant cross sectional drawings of the pump house, compressed air air station etc. with specification and bill of material.
c)
Dimensioned general arrangement drawings of all equipment.
d)
All relevant basic design calculations supporting the selection of equipment, location of valves, specials and supports along with forces and moments of fixed support.
Ducting including Supply Air Diffusers with Volume Control Dampers a) Duct : Material, thickness & quantity b) Damper: material, thickness, size, quantity c) Supply Air Diffuser: material, thickness, size, quantity
5.3
Ventilation Systems a) b) c) d) e) f) g) h) i) j)
Type of ventilation system Capacity of each ventilation system Make of equipment Design heat load for each premise Indoor climatic condition to be maintained Power requirement of each system Air change/hr Any specific design consideration Noise level at 1 m distance from the ventilation equipment Noise level at served premises
Technical Specification:Sec-9,Miscellaneous
Page 37 of 55
5.4
Centrifugal Fan a) Make & Model No b) Quantity, no. c) Type of blade d) Capacity, m3/h e) Total pressure, mm WC f) Speed, rpm g) Shaft power, KW h) Total Efficiency, % i) Motor rating, KW/ pole j) Fan Characteristic Curve k) Impeller Diameter, mm l) Velocity at inlet & outlet of fan, m/sec m m) Weight of fan and motor, kg n) Coupling details o) Vibration isolator type & quantity p) Thickness of scroll, blade, Back plate, shaft mm q) Noise level at 1m distance r) Overall size s) Drive Motor rating suggested
5.5
Fan Drive Motor Details a) Type & make b) Voltage, phase & frequency c) Rated power d) Speed e) Starting/ pull out torque f) Line current g) Starting current h) Overall efficiency i) Class of insulation j) Type of enclosure k) Any other information
5.6
Exhaust fan a) Make & Model b) Capacity in m3/h. c) Total Pressure, mm WC d) Material of construction and its thickness e) Speed in rpm. f) Drive details. g) Shaft Power consumption. h) Wheel diameter i) Efficiency j) Static & Dynamic weight of fan & motor assembly
Technical Specification:Sec-9,Miscellaneous
Page 38 of 55
k) Critical speed of fan l) Noise level at 1m distance in dB(A m) Performance curve. n n) Air flow direction. o o) Fixing details. p p) Vibration level. 5.7
Dry Panel type filter a) Make & Model b) Capacity in m3/h c) Pressure drop in mmWC. – both in clean & in dirty condition d) Effective cross sectional area in m2 e) Velocity through filter in m/sec. f) Material of filtering panel. g) Cleaning efficiency Vs particle size h) Methods of surface regeneration. i) Filter box construction details. j) Overall dimensions & no. of filters. k) Fixing frame details. l) Total weight.
5.8
Air Washer Unit a) Make & Model No. b) Type of unit (Horizontal/vertical) c) Overall dimensions (mm) d) Weight (kg) with and without water Capacity in m3/h. e) Total Pressure drop, kgf/ m2 g f) Material, dia and nos. of nozzles g) Make up water requirement h) Details of makeup, overflow, drain, supply & return water pipe lines i) Saturation efficiency j) Amount of water and its pressure at the nozzle k) Casing and tank thickness l) Water tank capacity
5.9
Centrifugal Pump (indicate separately for ventilation and dust suppression) a) Make and model no. b) Type of pump c) Capacity in m3/hr. d) Total head in m WC. e)Quantity f) Material of construction g) Shaft h) Impeller Casing i) Pump speed (rpm)
Technical Specification:Sec-9,Miscellaneous
Page 39 of 55
j) Shaft power k) Drive details a. Motor make b. Motor KW c. Insulation class d. Frame size l) Bearing type & make m) Type of coupling n) Vibration level o) Noise level at 1 m distance from pump set 5.10 Dry Fog & Plain Water Sprinkling type Dust Suppression Systems a) Technical details and quantity of main equipment including Nozzles, PRU, FAS and Instrumentation for Auto Operation. b) Technical details and quantity quantity of auxiliary equipment including air compressors, pumps, etc. c) Technical details of circular swiveling sprinklers d) Compressed air & water requirement, capacity of compressor, air receiver, capacity of water pump unit etc. e) Total power consumption. Capacity of each motor for pump and compressor. f) Details of air & water pipelines with sizes and quantities. g) Details of valves and fittings h) Details of solenoid valves, sensors, pressure gauges and other instruments. i) Details of tanks j) Details of hood / skirt boards modification k) Size of compressor cum pump house. l) Size of only pump house (In case compressed air is not provided) 5.11 Split Air – Conditioner a) Make & Model b) Quantity c) Capacity in TR (Nominal / Actual d) Air Flow m3/h e) Flow direction and volume control grill f) Material of construction g) Compressor type h) Drive details and total power consumption i) Overall dimensions j) Refrigerant type k) Filter efficiency
Technical Specification:Sec-9,Miscellaneous
Page 40 of 55
l) m) n) o) p)
Weight of unit Noise level at 1m distance in dB(A) Fixing details. Vibration level. Accessories included
Drawings/documents for Fire Protection System
6.0
Drawings/documents to be furnished with offer The tenderer shall submit the offer along with the following drawings / documents. a)
Scope of work with general description of the system system and equipment offered specifying the important features. The tenderer has to give a confirmation with respect to the scope of work as detailed in this specification excepting for the deviations, if any, to be listed in the schedule of deviation. The description description to be accompanied by single line diagrams, and equipment layout to enable the Purchaser to have a proper appreciation of the equipment offered and its operation.
b)
Specific exclusions, if any, from scope of work .
c)
Block Scheme diagram for all fire protection system along with tentative BOQ for major equipments.
d)
Specification of equipment along with their makes/catalogues and material of construction.
e)
Reference list of job executed for each type of system.
f)
List of mandatory spares as per requirement requirement for 2 years operation and maintenance.
g)
List of special tools and tackles.
h)
Amp. hour capacity of DC battery required for MFAP.
i)
Write up with control schematic on working of all fire protection systems.
j)
Detector type and Catalogues
k)
Linear heatt sensing cable details
Technical Specification:Sec-9,Miscellaneous
Page 41 of 55
Format - 1 1.0
FORMAT FOR GENERAL AND COMMERCIAL PARTICULARS 1. 2. 3.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14
15. 16. 17. 18. 19. 20. 21.
Name and Address of Bidder. Telegraphic Address of Bidder Name and designation of the person to whom all references shall be made to expedite technical coordination Place of Manufacturer Proposal No. & Date Current Registration No. with D.G.S. & D Whether all service facilities available? Whether necessary spare parts available? Has tenderer paid Earnest Money Deposit? Is offer valid for four (4) months from Price bid opening? Has bidder quoted F.O.R site prices? Is price break up given in Price Bid? Are prices quoted FIRM? (Price should be firm.) Is the tenderer agreeable to the terms of payment? If not, has terms of payment acceptable to him been indicated? Does the tenderer agree to the delivery periods indicated? Are the delivery periods guaranteed under penalty clause? Is the tenderer agreeable to pay 10% Security Deposit? Are all schedules for technical particulars and prices filled in? Has tenderer brought out all deviations in schedule of deviations? Warranty period from takeover of plant / equipment. Are equipment guaranteed as per various guaranteed clauses of tender documents? SIGNATURE ___________________ DESIGNATION ___________________ COMPANY ____________________ DATE ____________________
COMPANY SEAL
Technical Specification:Sec-9,Miscellaneous
Page 42 of 55
Format - 2 2.0
FORMAT FOR BIDDERS EXPERIENCE LIST Sl. No
Purchaser Location
1
2
3
& Customer’s PO No. and Date 4
Period & Details Year of of work Completion 5 6 7
Capacity of plant 8
Total cost of work done by bidder 9
NOTE: Bidder may also furnish the above details for ongoing assignments.
SIGNATURE ___________________ DESIGNATION ___________________ COMPANY ____________________ DATE ____________________
COMPANY SEAL
Technical Specification:Sec-9,Miscellaneous
Page 43 of 55
Format - 3 8.0
LIST OF DRAWINGS ENCLOSED WITH BID Sl. No. 1
Drawings 2
Title 3
SIGNATURE ___________________ DESIGNATION ___________________ COMPANY ____________________ DATE ____________________
COMPANY SEAL
Technical Specification:Sec-9,Miscellaneous
Page 44 of 55
SCHEDULE OF COMPONENTS IN USE AT NALCO’S EXISTING COAL HANDLING PLANT, CPP, ANGUL Components schedule given below are for information to Bidders for standardization and interchangeability with existing Coal Handling Plant only. Bidders must take a note of o these components details while selecting a new supply to control the inventory level. A)
Conveyor Pulley Schedule Pulley Type
Pulley Diameter (mm) Drive/ 630 Discharge 630 Pulley 630 800 Non Drive 400 Pulleys 400 500 B)
C)
Face width (mm) 1150 1150 1150 1150 1150 1150 1150
Shaft Diameter (mm) 125 150 165 175 90 100 115
Bearing Diameter (mm) 115 140 150 160 75 90 100
Shaft length (mm) 1690 2095 2100 2120 1760 1760 1770
PlummerBlockCenter (mm) 1550 1650 1650 1650 1650 1650 1650
Bearing & Plummer Block Schedule. Shaft diameter (mm)
Bearing size
65 75 90 100 115 125 140 150 160
22215K 22217K 22220K 22222K 22226K 22228K 22232K 22234K 22236K
Plummer Block Schedule Drive Pulleys Non Drive Pulley 1 – 1328 - AL 1 – 1328 - AL 1 – 149 - AL 1 – 149 - AL M – 1034 - BL M – 1034 - BL M – 1033 - CL M – 1033 - CF M – 1035 - AL M – 1036 - AF M – 1036 - BL M – 1036 - BL M – 1035 - CL M – 1036 - CF 1 – 829 - AL 1 – 1330 – AF 1 – 1487 - L 1 – 1488 - F
Gear Box Schedule. Gear box size SZN-200 SZN-225 SZN-250 SZN-280 SZN-320 SZN-250 KDA-200 200
Technical Specification:Sec-9,Miscellaneous
Reduction Ratio 16 : 1 16 : 1 16 : 1 20 : 1 20 : 1 16 : 1 125:1
Page 45 of 55
D)
Fluid Coupling Schedule
Fluid coupling size FCU-16.25 16.25 FCU-17.75 17.75 FCU-23 FCU-41 E)
Baffle Ratio 1.5B 1.5B 1.5B 1.5B
Idler Schedule The idlers are drop in slot type.
Technical Specification:Sec-9,Miscellaneous
Page 46 of 55
LIST OF PREFERRED MAKES 1.1. MECHANICAL SL. NO. 1. 2. 3. 4.
5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
17. 18. 19. 20. 21 22
EQUIPMENT GEAR BOXES CONVEYOR BELTS
MAKE ELECON, FLENDER, SHANTHI, SEW, NAW, GRAEVES DUNLOP, NIRLON, MRF, PHOENIX, NORTHLAND, FORECH, ANIL RUBBERS, ORIENTAL. IDLER ELECON, TRF, KALI, KRUPP, MACMET, HINDUSTAN UDYOG PULLEY ELECON, TRF, KALI, HEC, HINDUSTAN UDYOG, McNALLY BHARAT, HITECH, MASYC, KRUPP, SIMPLICITY, ARUDRA, MACMET. BEARINGS SKF, FAG, NTN, NBC, NORMA, TATA, EAST EUROPIAN, EUROPIAN ZKL SLEW RING BEARINGS ROTHE ERDE, TITANUS, LYC-CHINA FLEXIBLE COUPLING FMG, DAVID BROWN, HICLIFF, CONCORD, ROMA, WELLMAN INCAD. GREAVES LTD., NAW, GBM, ALLFLEX FLUID COUPLING PEMBRIL, FLUDOMAT, VOITH, ELECON FASTENERS GKW, SUNDERAM, PRECISION FASTENERS MANUAL HOISTS WH BRADY, KANUBHAI, HERCULES, TRACTEL TIRFOR, REVA ENGG. MM ENGRS, BRADY&MORRIS OIL SEALS VACCA, RUBBER EQPT. & ENGG. CO. L TD LUBRICATION TECALEMIT, SURMAC, LUBCON, PRAKASH, AFMC, HELIOS PROTOS, LINCOLN HELIOS POWER PACK REXROTH, PARKER, ETON, YUKEN, VICKERS, HAGGLUNDS HYDRAULICS REXROTH, YUKEN, CARTER, VELJAN CYLINDERS UTL, MONTECH, WIPRO, OSCAR, HAGGLUNDS, PARKERCALZONI HOSES AEROLEX, GATES INDIA PVT. LTD a) BELT CLEANERS a) HOSCH, KAVERI,TECHNOFAB, PROMAC, BMH CONCARE b) SKIRTS AND SKIRT b) UNITED TECHNO MECH, TEGA, KAVERI, HOSCH SEALING ARRANGEMENT ACTUATOR OPERATED UNITED TECHNOMECH, PREPEC, PEBCO FLAP GATES IN LINE MAGNETIC ELECTRO-ZAVOD, ZAVOD, MBIL, ELECTROMAG, POWER BUILD, MCI, SEPARATORS ELECTROMAGNETIC INDUSTRIES BELT WEIGH SCALES SCHENK-JENSON, JENSON, TRANSWEIGH, IPA, SARTORIUS BELT SWITCHES JAYSHREE, SCHNEIDER, TELEMECHANIC, INDUSTRY SYNDICATE, PROTO CONTROL BRAKES BCH, INDUSTRIES SYNDICATE, STORM KRAFT, ELECTROMAG, SPEED O CONTROL, STROMAG ELEC. HOISTS ARMSEL, SHIVPRA, WH BRADY, BRADY & MORRIS, GRIP ENGRS., HI-TECH, TECH, CENTURY CRANE, TUOBRO FURGUSON, UNITECH
Technical Specification:Sec-9,Miscellaneous
Page 47 of 55
In case the Tenderer/ Contractor intends to substitute any particular make of equipment / components/ ents/ materials by their/ his own make other than that listed in this document, the Tenderer shall clearly bring out the same in his tender along with justification and indicate the makes offered by him. It will be prerogative of the Purchaser to accept or reject the tenderer’s own makes so offered. 1.2.
ELECTRICAL Sl.No 1.
ITEM 415 V MCC/ (Drawout type)
2.
415 V PDB/DB (Fixed type)
3.
HT Cables
4.
LV Motors
5.
Local Control Stations (Weather Proof)
6.
Bimetal Relays
7.
Contactors
8
Control Switches
Switches/Selector
Technical Specification:Sec-9,Miscellaneous
APPROVED SUB VENDORS 1. ABB 2. GE Power Control Ltd 3. L&T 4. Siemen Ltd 5. Schneider Eectric India Pvt.Ltd 1. Control & Switchgear Co. Noida 2. GE Power Control Ltd 3. L&T 4. Schneider Eectric India Pvt.Ltd 5.ABB 6.SIEMENS 1. CCI 2.Universal 3.Polycab 4.NICCO 5.KEI 1. Alstorm 2. Asea Brown Boveri Ltd, Faridabad 3. Bharat Bijlee 4. Kirloskar Electric Co.Ltd, Banbalore & Hubli 5. Siemens 6. CGL 1. Bhartiya Industries 2. Baliga Lighting Eqpt(p)Ltd 3. Ex-protecta 4. Electrical Equpt.Corporation 5. Flexpro Electricals Pvt.Ltd 6. Prompt Engineering Works 1. ABB,Bangalore 2. Bhartiha Industries 3. L&T 4. Siemens 5. Schneider Eectric India Pvt.Ltd 1. ABB,Bangalore 2. Bhartiha Industries 3. Control & Switchgears Contactors Ltd. 4. GE Power Control India Ltd 5. L&T 6. Siemens Ltd 7. Schneider Electric India Pvt.Ltd 1. Alstom Ltd 2. Havells India 3. Hotline Switchgear &Controls 4. Kaycee Industries 5. L&T
Page 48 of 55
9.
Fuse Switch
10
Timers
11
Fuse
12
ELCBs
13.
MCBs
14
MCCBs
15
Meters
16
Push Buttons & Indicating Lamp
Technical Specification:Sec-9,Miscellaneous
6. Reliable Electronic Components Pvt. Ltd 7. Siemens Ltd 8. Switron Devices 1. ABB Ltd, Bangalore 2. Control & Switchgears Co Ltd 3. Havells India 4. Indo Asian Fuse Gear 5. L&T 6. Siemens Ltd 7. Standard Electricals 8. Alstom 9. Schneider Electric India Pvt.Ltd 1. Bhartiha Industries 2. Concord Controls 3. Electronic Automation Pvt Ltd 4. L&T 5. Siemens Ltd 6. Schneider Electric India Pvt.Ltd 1. GE Power Controls 2. Indo Asian Fuse Gear 3. L&T 4. Siemens Ltd 5. Ferraz 6. Bussman 1. Datar Switchgear Pvt Ltd 2. Indo Asian Fuse Gear 3. Legrand India 4. ABB 5. Siemens 6. Schneider Electric India Pvt.Ltd 7. GE 1. Datar Switchgear Pvt Ltd 2. Havells India 3. Indo Asian Fuse Gear 4. Indian Current Control 5. Legrand India 6. Standard Electricals 7. ABB 8. Siemens 9. GE 10.L&T 1. GE Power Controls 2. L&T 3. Schneider Electric India Pvt.Ltd 4. Siemens 5. ABB 1. Automatic Electric 2. Meco Instruments Pvt Ltd 3. Nippen Electrical Instruments Co 4. Risabh Instruments Pvt.Ltd 5. Industrial Meters(P) Ltd 1. Bhartiha Industries 2. Concord Controls 3. Control & Switchgears Co Ltd 4. Hotline Switchgears & Controls 5. L&T
Page 49 of 55
17
Lighting & Power panels
18
Lighting Fixtures
19
Terminal Blocks
20
Switch socket outlets
21
Transducer
22
LT Transformer
23
PLC
24
UPS
25
Control Desk
27
VVVF Drive
29.
33 K V Isolator
30
Trailing Cables
Technical Specification:Sec-9,Miscellaneous
6. Precifine Products Pvt. Ltd 7. Siemens 8. Shri Tulsi Switchgears 9. Teknick Controls 10. Schneider Electric India Pvt.Ltd 11. Binoy Opto Electrics,Kolkata 1. Control & Switchgears Co Ltd 2. Havells India 3. Masstechm Switch gear 4. Legrand India 5. Standard Electricals 1. Bajaj Electricals 2. Comptron Greaves 3. Philip India 1. Essen 2. Connect well 3. Elmex 1. ALSTOM 2. CGL 3. B & C 4. ESSEN 1. ABB 2. MECO 1.CGL 2.KEC 3.BBL 4.BHEL 5.AREVA 6.BMCC 7.T&R 8.VIJAY ELECTRICAL 1.GE-FANUC 2. ALLEN BRADLY 3.SCHNEIDER 1.EMERSION 2.HI-REL 3.NUMERIC 4.TATA LIBERT 1. SIEMENS 2. ALSTOM 3. L&T 4. ABB 1. ALSTOM 2. BHEL 3. DANFOS 4. L&T 5. NELCO 6. ROCKWELL 7. SIEMENS 8. ABB 9. SCHNEIDER 10. YASKAWA 1. PANICKER 2. BOND STRANDS 3. DRISCHER 1. KEI 2. NICCO
Page 50 of 55
3. UNIVERSAL 31
HT Switch gear
32
HT Transformer
33
33KV VCB
34
Protection relays
35
Breaker Control switches
36
LV CT/PT
37
HVCT/PT
38.
Solid State Annuncitaor
39.
Lightning Arrests
1.WSI 2.ELPRO.
40. 41.
33KV Air Break switch High Mast Tower
42. 43. 44.
Cable accessories ACSR/AAAC Conductor 415V PCC
45.
Cable termination 7 jointing kits LT power and control cables
1.DRIESCHER PANNIKER 1.BAJAJ 2.PHILIPS 1.DOWELLS 1.RELIANCE CONDUCTORS 1. L&T 2.SIEMENS 1.RAYCHEM RPG
46.
Technical Specification:Sec-9,Miscellaneous
1. BHEL 2 Siemens 3. ABB 1. BHEL 2 Siemens 3 TELK 4 ABB 5 AREVEA 1. ALSTOM 2.ABB 3.SIEMENS 1.ABB 2.ALSTOM 3EASUN REY ROLLE LTD 4L&T (FOR NUMERICAL RELAYES ONLY) . 5SIEMENS (FOR NUMERICAL RELAYES ONLY) . 1.ALSTOM RELIABLE ELECTRONIC COMPONENT PVT.LTD. 2.RELIABLE 3.SWITORN DEVICES 1.COTROL AND SWITCH CO.LTD. 2.GEILBERT & MAXWELL ELECTRICAL 3.KAPPA ELECTRICALS 4.L&T 5.NARYAN POWER TRON PVT.LTD. 6.SILKAANS ELECTRICAL 7.PRECISE ELECTRICAL 8.PROGATI ELECTRICAL PVT.LTD. 1.AE 2.BHEL 3.CGL 4.SILKAANS 5.JYOTI 6.KAPPA 7.ABB 8.PROGATI. 1.APLAB 2.MINILEC 3.IL
1.CCI 2.UNIVERSAL 3.POLYCAB 4.NICCO
Page 51 of 55
1.3.
1.3
47.
Signal cable
and
48.
VRLA battery
49.
Battery charger
Instrumentation
5.KEI 6.CORDS 7.GEMSCAB 1.CCI 2.UNIVERSAL 3.POLYCAB 4.NICCO 5.KEI 6.CORDS 7.GEMSCAB 1.AMAR RAJA 2.EXIDE 1. AMAR RAJA 2.CHABI ELECTRICAL 3.CALDYNE 4.HBL NIFE
AIR CONDITIONING, VENTILATION & DUST SUPPRESSION SYSTEM - EFE, C. Doctor, Voltas Ventilation system Dust Suppression System - TPS, Kaveri, F. Harley Air Conditioning system - Blue Star, Voltas, Carrier CIVIL CEMENT- ACC,L&T Ultra Tech, Zuari, RAASI GOLD or equivalent approved manufacturer. REINFORCEMENT STEEL-SAIL,Tata STEEL SAIL,Tata Steel, RINL, or equivalent approved manufacturer. Note: elsewhe in 1. Makes indicated above shall also be read with preferred makes as listed elsewhere this specification. 2. For make of any item, not appearing in the above list, specific approval shall be taken by the bidders from Purchaser.
Technical Specification:Sec-9,Miscellaneous
Page 52 of 55
1.0
LIST OF TOOLS AND TACKLES S.NO 1. 2.
3.
4.
5. 6.
7.
8. 9. 10. 11 12. 13. 14
15.
DESCRIPTION QUANTITY Manually operated Hydraulic Jack 2 Nos i) 50T X 150 mm stroke Bastard (Rough Cut) Files 250 mm size i) Flat 1 No. ii) Round 1 No. 1 No. iii) Half Round 1 No iv) Triangular Fine Cut Files 250 mm size i) Flat 1 No. ii) Round 1 No. iii) Half Round 1 No. iv) Triangular 1 No Adjustable Outside Micrometer Interchangeable Anvil Type i) 0-150 mm 1 No. ii) 150 – 600 mm 1 No Inside Micrometer i) 50 – 150 mm 1 No Vemier Calipers – i) 0-150 mm size 1 No. ii) 0 – 300 mm size 1 No Feeler Gauge i) 10 mm thk. 6 inch 1 No. ii) 10 mm thk. 12 inch 1 No Sprit Level i) 150 mm 2 No Torque Wrench with socket 75 – 150 kg.m 1 set Standard Ring spanners (Upto 32 mm ) 1 set Standard D.E. spanners (Upto 32 mm ) 1 set Adjustable spanners (Upto 50 mm each set of 3 Nos.) 1 set Socket Head Spanners (Box Spanners 10 to 32 mm ) 2 set Sledge Hammers i) 5 kg. 2 Nos. ii) 10 kg 2 Nos Nylon Faced Hammers (4 Sizes) 1 set
Technical Specification:Sec-9,Miscellaneous
Page 53 of 55
16. 17 18. 19.
20
21.
22.
23 24 25. 26. 27 28. 29 30. 31 32
33 34. 35.
36. 37 38 39
4” dia portable motor operated grinding m/c with flexible grinder Ball Pein Hammers in different sizes. Dial Gauge 0-10 0 mm LC-0.01 mm with mag. Stand Steel Tapes i) 3 m Size ii) 6 m Size Steel Scales i) 0.3 m Size ii) 0.5 m Size Internal Calipers i) 150 mm Size ii) 300 mm Size External Calipers i) 150 mm Size ii) 300 mm Size Hand operated Hacksaw Frame with 1 Doz. Blades (12”) Tri-square square (6” x 12”) Screw Operated Coupling and Bearing Puller – 300 mm Size Grease Gun with hose & adopter (Manual) Bucket Grease Gun (Manual) Self supporting, extendable aluminum ladder with maximum height of 6m Hydraulic flange puller of reputed make Pipe Wrenches – 6” & 12” Digital Tachometer (0 – 3000 rpm) Screw Drivers i) 150 mm Size ii) 300 mm Size Sling with Eye Bolt and D-Shackle D of 2,3,5 &10 tonnes Plum Bobs All types of Pliers of different size of reputed make to suit the eqpt. i) Cutting pliers ii) Internal Circlip iii) External Circlip Adjustable Pliers Marking Punches Scribers Insulation resistance Tester (Megger) i) 500 V ii) 1000 V
Technical Specification:Sec-9,Miscellaneous
2 Nos 6 Nos 2 Nos
1 No. 1 No 1 No. 1 No 1 No. 1 No 1 No. 1 No 1 Set 2 Nos 2 Nos 2 Nos 1 No 2 Nos 2 Sets 4 Nos 2 Nos 2 Nos. 2 Nos 2 Sets 2 Nos
2 Nos. 2 Nos. 2 Nos 2 Nos 2 Sets 4 Nos 1 No. 1 No
Page 54 of 55
40. 41. 42. 43. 44. 45 46 47 48. 49 50 51 52 53.
2.0
Tong Tester Portable Emergency Light (Hand Torch with Dry Cells) 100 W Hand Lamp with 50 M Flexible Wire Hand drills (pistol) Digital Multimeter Digital Clamp meter Hand drill – Electrical ½ “ & 1” Crimping Tool ( Hand Operated) - 5 mm2 to 16 mm2 Crimping Tool ( Hand Operated) -16 mm2 to 240 mm2 Milli Ohm Meter Combination Plier Nose Plier Earth Megger Phase Sequence meter (0 – 415V)
2 Nos 2 Nos 2 Nos 2 Nos 1 No 1 No 2 Sets 1 Set 1 Set 1 No 2 Nos 2 Nos 1 No 1 No.
LIST OF TENDER PURPOSE DRAWINGS FOR BIDDER’S REFERENCE SL. NO. 1
DESCRIPTION DRAWING NO Layout of Coal Storage Yard & 1034/Q6Q3/A-02A/LO 02A/LO-001 Rev 05 Handling System
(Set of three drawings)
2
Coal Flow Diagram
FD-CHP
3
General Layout of CPP, NALCO
6-08-0-07734-01
4
G.A. & Marking of Conveyor BC-115 BC
02728-M-BM-CS-GA--0027 Rev C
5
G.A. & Marking of Conveyor BC-103 BC
CKIH-3901-M0-B057 B057 Rev D
6
G.A. of Junction House JH-1 JH
CKIH-3901-M0-B004 B004 Rev C
G.A. of wagon tippler & receiving RITES/PORTS/NALCO/FS/L-01 RITES/PORTS/NALCO/FS/L 7
conveyor
Technical Specification:Sec-9,Miscellaneous
(Set of five drawings)
Page 55 of 55
Annexure - II Special Instructions to Bidders 1.0
COMPLETION SCHEDULE The schedule for completion in all respect as per Tender Documents from Brief Order (BO) date is specified in Instruction to Bidders.
2.0
DUE DATE Please ensure your offer, complete in all respects reaches us by the bid due date specified in Instructions to Bidders. Offers received after the bid due date and time will be considered as Late Offers and will not be considered.
3.0
PRICE FORMAT Please furnish the prices strictly as per the format enclosed. Prices shall not appear any where else in the offer, and if prices are mentioned any where else the same shall not be considered. Prices should be submitted in duplicate sealed super scribed envelope along with un-priced copies as per Tender documents (Un-priced copy of price bid should also be enclosed with un-priced copies with prices blanked out but “Quoted/ Not Quoted” marked against respective clauses).
4.0
VALIDITY OF BIDS The bid should be kept valid for acceptance for a period of 4 (four) months from the final due date for bid submission.
5.0
EVALUATION/ LOADING/ REJECTION CRITERIA
5.1
All evaluation shall be made on landed and erected on destination basis including design and engineering, supply of equipment, spares etc. (excluding One Year O&M Spares) and all other erection, construction, installation, supervision and commissioning charges along with the taxes and duties for the same, as per scope of Tender Documents.
5.2
Supply prices shall be evaluated as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
FOT Despatch Point Add ED & E-cess Add CST/ LST/ VAT Total Price Transit Insurance Freight Charges Total FOT Site Entry Tax Total Price Technical loadings, if any
Annexure II, Special Instructions to Bidders
: : : : : : : : : :
As quoted As Quoted As Quoted 1+2+3 0.25% on (4) As quoted 4+5+6 @ 2% on (7) 7+8 On FOT Despatch point price Page 1 of 9
11. 12. 13. 5.3
Commercial loading, if any CENVAT Benefit Total Comparable Price
: On FOT Despatch point price (-) 2 : 9+10+11+12
Price loading on account of payments and other conditions required by various vendors will be based on following:(i)
Payment terms: a)
(ii)
Price loading on account of payment terms at variance with Bidding Document payment terms will be loaded @ 12% per annum for the relevant period.
Price Variation:Terms offered by vendor price loading (a)
Firm Price
:
No loading
(b)
In case of ceiling on Price Variation Clause
:
Loading by ceiling percentage offered
(c)
No ceiling on the formula
:
Offer may be rejected
(d)
No formula and no ceiling specified by vendor
:
- do -
(iii)
Vendors should quote firm inland freight charges from dispatch point to Site at Angul, Orissa. If a vendor does not quote firm inland freight charges then their offer will be loaded with maximum of the inland freight charges as quoted by the other bidders from that region or based on estimation by NALCO in case there is no other offer from that region.
(v)
Any differential in taxes and duties will be cost loaded on case-to-case basis. If a vendor states that taxes/duties are not applicable at present and will be charged as applicable at the time of delivery then no advantage will be given.
(vi)
All materials are required to be transported by Bank-approved carriers, preferably having an office at the place of concerned unit.
(vii)
Cost loading in respect of utilities will be considered where guaranteed consumptions have been asked in NIT as per methodology defined in the NIT.
5.4
All cost loadings will be calculated on F.O.T. despatch point prices.
5.5
No deviation to terms & conditions of the bid documents is allowed. Further Non acceptance of following commercial clauses shall lead to rejection of bid:
Annexure II, Special Instructions to Bidders
Page 2 of 9
(i)
Bids that do not meet the qualification criteria as specified in the NIT/ bid documents shall be summarily rejected.
(ii)
A bid with incomplete scope of work and / or which does not meet the technical specifications and requirements as specified in the NIT documents shall be considered as non-responsive and rejected.
(iii)
Prices must be furnished in accordance to the price schedule format enclosed and strictly based on the terms specified related to the bid prices in the instructions / conditions. Non compliance to this requirement shall make the bid liable for rejection.
(iv)
Bidders are requested to note that exceptions / modifications taken by them to the following clauses of Tender Documents - Commercial may result in rejection of their bid :(a) (b) (c) (d) (e) (f)
6.0
Proforma of Bank Guarantee for Advance Payment, if any, and Contract - cum Performance Bank Guarantee Contract Performance Guarantee clause Completion Schedule Period of validity of bid Guarantee / Warranty Replacement of Defective parts and materials
REFERENCE LIST The bidders are requested to submit a list of buyers to whom the same or similar type of equipment have been supplied by them and which are under operation. The detailed addresses of such buyer’s office/works including Telephone, Fax Nos. and Contact Person and Order Reference are to be mentioned.
Annexure II, Special Instructions to Bidders
Page 3 of 9
APPENDIX - A TO SPECIAL INSTRUCTIONS TO BIDDERS INDEX SL. NO.
DESCRIPTION
1.0
COST OF BIDDING
2.0
SITE VISIT
3.0
BIDDING DOCUMENT
4.0
CLARIFICATION OF BIDDING DOCUMENT
5.0
AMENDMENT OF BIDDING DOCUMENT
6.0
CONFIDENTIALITY OF BIDDING DOCUMENT
7.0
LANGUAGE OF BID
8.0
FORMAT AND SIGNING OF BIDS
9.0
MODIFICATION & WITHDRAWAL OF BIDS
10.0
OPENING OF UN-PRICED BIDS
11.0
OPENING OF PRICE BIDS
12.0
COMPARISON OF BIDS
13.0
CONTACTING THE OWNER/CONSULTANT
14.0
AWARD CRITERIA
15.0
OWNER’S/CONSULTANT’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL BIDS
17.0
ISSUE OF ORDER
Annexure II, Special Instructions to Bidders
Page 4 of 9
1.0
COST OF BIDDING
1.1
All direct and indirect costs associated with preparation and submission of bid (including clarification meetings and site visit, if any) shall be to bidder’s account and NALCO / RITES, will in no case, be responsible or liable for these costs, regardless of the conduct or outcome of the bidding process.
2.0
SITE VISIT
2.1
Bidder is advised to visit and examine the Site, its surrounding and familiarize himself of the existing facilities and environment and collect all other information which he may require for preparing and submitting the bid and entering in to the contract. Claims and objections due to ignorance of existing conditions or inadequacy of information will no be considered after submission of the bid and during implementation.
2.2
The bidder or any of his personnel or agents will be granted permission by the Owner to enter upon his premises and land for the purpose of such inspection but only upon the explicit condition that the bidder, his personnel or agents will release and indemnify the owner and his personnel or agents from and against all liability in respect thereof and will be responsible for personnel injury (whether fatal or otherwise), loss of or damage to property and any other loss, damage, cost and expenses incurred as a result thereof.
2.3
For site visit, the intending bidder may contact General Manager (CPP), NALCO, Angul, Orissa Phone- 06764- 220 158, Telefax – 06764- 220 646 or General Manager (Projects), RITES Ltd, Bhubaneswar, Phone: 0674 2572690, 09438677075. Fax – 0674 2575 284. or Sr. DGM(Civil)/RITES, Bhubaneswar, phone-09437283829.
3.0
BIDDING DOCUMENT
3.1
The Bidder is expected to examine all instructions, forms, terms and specifications in the Bidding Document. The Bidding Document together with all its attachments thereto, shall be considered to be read, understood and accepted by the Bidder, unless deviations are specifically stated in seriatim (giving reference s. no. of Bidding Document) by the Bidder. Failure to furnish all information required by the Bidding Document or submission of a bid not substantially responsive to the Bidding Document in every respect will be at Bidder’s risk and may result in the rejection of his bid.
3.2
The Bidders must fulfill the Qualification Criteria given in the Instructions to Bidders and furnish all necessary documentary evidence in support of Bidder’s experience/ capability as required, along with the bid. In the absence of the requisite documents, NALCO / RITES reserves the right to reject the bid without making any reference to the Bidder. Bidders must make their own judgment on the adequacy of the documents/ information they provide. In case any information provided by Bidder is found to be incorrect, the bid will be rejected, and the Earnest Money Deposit of such Bidder will be liable for encashment. Bidder must buy Bidding Document by paying the requisite document fee before the sale closing date & time. In case the Bidding Document is downloaded from website t h e requisite Bidding Document Fee in the form of DD payable to NALCO shall accompany the bids.
3.3
Annexure II, Special Instructions to Bidders
Page 5 of 9
4.0
CLARIFICATION OF BIDDING DOCUMENT AND PRE-BID MEETING
4.1
Bidder shall examine the bidding document thoroughly in all respect and if any conflict, discrepancy, error or omission is observed, bidder may request clarification within the cutoff date and 3 weeks prior to the bid closing date. Such clarifications request shall be addressed to the following: GM (Projects), RITES Ltd.,Regional Project Office, Bhagwan Tower(1st Floor), Cuttack Road, Bhubaneswar -751006, Phone:-0674-2575493, Fax:0674-2575284, E-mail :
[email protected]
4.2
Any failure by bidder to comply with the aforesaid requirement shall not excuse the bidder, after subsequent award of contract, from performing the work in accordance with the contract.
4.3
Response to queries/ clarifications raised will be sent as expeditiously as possible. The response shall not form part of the bidding document unless issued as an addendum/ amendment.
4.4
Bidders are expected to resolve all their clarification/ queries to the bidding document and submit their bid in total compliance to biding document without any deviation/ stipulation/ clarification.
4.5
PRE-BID MEETING The Tenderer or his official representative is invited to attend a pre-bid meeting which will take place at the Office of General Manager(Project), CPP, Nalco,Angul on 10.09.2012 at 10.30 hours. The Tenderers are required to submit any question on issues relating to the tender, in writing or by telefax or by E-mail so as to reach general Manager(Project), RITES Ltd.,Regional Project Office, Bhagwan Tower(1st Floor), Cuttack Road,Bhubaneswar -751006 not later than 3 (three) days before the date fixed for the meeting. The purpose of the meeting will be to clarify the issues raised and to answer supplementary questions on such issues. Minutes of the meeting including the text of the questions raised (without identifying the source of enquiry) and the responses given will be uploaded on RITES website. Any modifications of the Tender Document which may become necessary as a result of the Pre-bid Meeting shall be made exclusively through the issue of an Addendum / Corrigendum and not through the Minutes of the PreBid Meeting. The Minutes of the Meeting as described above and the Addendum / Corrigendum, if any, will be uploaded on RITES website only. Non-attendance at the Pre-bid Meeting will not be a cause for disqualification of a tenderer.
5.0
AMENDMENT OF BIDDING DOCUMENT
5.1
At any time prior to the bid due date, NALCO / RITES may, for any reason, whether at its own initiative or in response to a clarification requested by a prospective Bidder, modify the Bidding Document and issue amendment in the form of Addendum.
Annexure II, Special Instructions to Bidders
Page 6 of 9
5.2
Any addendum thus issued will become part of bidding document and bidder shall submit original addendum/ compliance letter duly signed and stamped in token of his acceptance.
5.3
In order to afford prospective Bidders, reasonable time in which to take the amendment into account in preparing their bids, NALCO /RITES may, at its discretion, extend the bid due date.
6.0
CONFIDENTIALITY OF BIDDING DOCUMENT
6.1
Bidders shall treat the biding documents and contents therein as strictly confidential.
6.2
The bidding document is and shall remain the exclusive property of the OWNER without any right to bidder to use them for any purpose except for the purpose of bidding.
7.0
LANGUAGE OF BID
7.1
The bid prepared by the Bidder and all correspondence/ drawings and documents relating to the bid exchanged by Bidder and NALCO /RITES shall be written in ENGLISH language. Any printed literature furnished by the Bidder written in another language should be accompanied by an ENGLISH translation. In case of any conflict, for the purpose of interpretation of the bid, the ENGLISH translation shall govern.
8.0
FORMAT AND SIGNING OF BID
8.1
The Bidder shall prepare required number of copies of the bid, clearly marking each ‘Original Bid’ and ‘Copy of Bid’ as appropriate. In the event of any discrepancy between them, the ‘Original Bid’ shall govern.
8.2
The original and all copies of the bid shall be typed or written in indelible ink and shall be signed by the Bidder or a person duly authorized to bind the Bidder to the Contract. The name and position held by each person signing must be typed or printed below the signature. The person or persons signing the bid shall initial all pages of the bid, except for unamended printed literature.
8.3
The complete bid shall be without alterations, interlineations or erasures, except as may be necessary to correct errors made by the Bidder, in which case such corrections shall be rewritten & initialed by the person or persons signing the bid.
9.0
MODIFICATION AND WITHDRAWAL OF BIDS
9.1
The Bidder may modify or withdraw his bid after the bid’s submission, provided that the modification/ withdrawal notice is received by the Owners/ Consultant prior to the bid due date & time. The Bidder’s modification or withdrawal notice shall be prepared, sealed, marked and despatched in accordance with the provisions of Bidding Document. A withdrawal notice may also be sent
Annexure II, Special Instructions to Bidders
Page 7 of 9
by Cable or Telefax but must be followed by a signed confirmation copy dated not later than the deadline for submission of bids. 9.2
No bid shall be modified subsequent to the due date & time or extension, if any, for submission of bids.
9.3
No bid shall be allowed to be withdrawn in the interval between the deadline for submission of bids and the expiration of the period of bid validity specified by the Bidder. Withdrawal of a bid during this interval shall result in the forfeiture of Bidder’s Earnest Money Deposit .
10.0
OPENING OF UN-PRICED BIDS
10.1
Un-priced part of the Bid shall be opened in the RITES, Bhubaneswar Office, in the presence of Bidder’s representatives (duly authorized by a competent person and having the Letter of Authority who choose to attend, on date, time as mentioned in the Instructions to Bidders. The Bidder’s representatives, who are present, shall sign a register evidencing their attendance. Bidders’ whose bids are not opened for any reason, including non-receipt of original Earnest Money Deposit, will not be allowed to be present during bid opening.
10.2
The Bidder(s) names, modifications, bid withdrawals and the presence or absence of the requisite Earnest Money Deposit and such other details as the NALCO/RITES, at its discretion, may consider appropriate will be announced and recorded at the time of opening of un-priced bids as specified in the Instruction to Bidders/ Tender Documents.
11.0
OPENING OF PRICE BIDS
11.1
Bidders’ found to be substantially responsive a n d t e c h n o - c o m m e r c i a l l y a c c e p t a b l e will be advised of date & venue for the priced bid opening. Bidders may depute their authorized representative, along with letter of authority to attend price bid opening. The price bids of those Bidders determined to be not substantially responsive will be rejected and will not be called for price bid opening. The Bidder’s names, bid prices, modifications and bid withdrawals and such other details as the Consultant, at its discretion, may consider appropriate, will be read out at the time of opening of priced bids of technically and commercially acceptable Bidders.
12.0
COMPARISON OF BIDS
12.1
The Consultant will evaluate and compare bids previously determined to be substantially responsive pursuant to the provisions of the Bidding Document.
12.2
Arithmetical errors will be rectified on the following basis:If there is a discrepancy between the unit price and the total price that is obtained by multiplying the unit price and quantity, the unit price shall prevail and the total price will be corrected. If there is a discrepancy between the total amount and the sum of total prices, the sum of the total prices shall prevail and the total bid amount will be corrected. Further, if there is a
Annexure II, Special Instructions to Bidders
Page 8 of 9
discrepancy between the quoted lump sum price, and its separate break-up prices (if any), the quoted lump sum price shall prevail. 13.0
CONTACTING THE OWNER/ CONSULTANT
13.1
No Bidder shall contact the NALCO / R I T E S on any matter relating to its bid, from the time of bid opening to the time the Contract is awarded.
13.2
Any efforts by a Bidder to influence the NALCO / RITES in the Owner’s/ Consultant’s bid evaluation, bid comparison or contract award decisions may result in the rejection of the Bidder’s bid.
14.0
AWARD CRITERIA The Owner will award the Contract to the successful Bidder whose bid has been determined to be the lowest evaluated, responsive bid, provided further that the Bidder is determined to be qualified to satisfactorily perform the Contract.
15.0
OWNER’S/CONSULTANT’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL BIDS
15.1
NALCO / RITESO reserves the right to accept or reject any bid, and to annul the bidding process and reject all bids, at any time prior to award of contract, without thereby incurring any liability to the affected Bidder or Bidders or; any obligations to inform the affected Bidder or Bidders of the ground for the Owner’s/Consultant’s action.
15.2
The submission of any bid connected with these documents and specifications shall constitute an agreement that the Bidder shall have no cause for action or claim, against the Owner for rejection of his bid. The Owner shall always be at liberty to reject or accept any bid or bids at his sole discretion and any such action will not be called into question and the Bidder shall have no claim in that regard against the Owner. ISSUE OF ORDER The Owner will send to the successful bidder B rief Order/ Work Order incorporating all the terms and conditions agreed between the parties. Within 15 days of receipt of the Order, the Bidder shall sign and return it to the Owner for their records.
16.0 16.1 16.2
17.0 In case of contradiction between relevant Indian Standards, General Conditions of Contract, Special Conditions of Contract, Specifications, Drawings, Schedule of Prices / Rates, the following shall prevail in order of precedence: i) Brief of Order, Detailed Letter of Acceptance along with Statement of Agreed Variations (if any) and its enclosures. ii) Schedule of Rates. iii) Technical Specifications iv) Drawings. v) Addendum to Tender Documents (Commercial). vi) Tender Document Commercial(Indigenous). vii) Relevant Indian Standards / Specifications Annexure II, Special Instructions to Bidders
Page 9 of 9
.
TENDER DOCUMENTS COMMERCIAL (INDIGENOUS)
NATIONAL ALUMINIUM COMPANY LIMITED (A GOVT. OF INDIA ENTERPRISE) REGISTERED OFFICE: NALCO BHAVAN, P/1, NAYAPALLI, BHUBANESWAR - 751 061
Tender Documents Commercial (Indigenous)
Page 1 of 56
.
CONTENTS GENERAL CONDITIONS OF CONTRACT Sl. No.
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 22.00 23.00 24.00 25.00 26.00 27.00 28.00 29.00 30.00 31.00 32.00 33.00
Page No.
APPLICATION DEFINITION OF TERMS CONTRACTOR TO INFORM HIMSELF FULLY SCOPE OF WORK DESIGN REQUIREMENTS CONTRACT PRICE TAXES PERFORMANCE BOND PROTECTIVE PAINTING, PACKING & MARKING SHIPMENT PARTICULARS INSURANCE DELIVERY LIQUIDATED DAMAGES FOR DELAY IN COMPLETION IMPORT LICENSE AND FOREIGN EXCHANGE CONTRACTOR’S DOCUMENTS, DRAWINGS AND INSTRUCTION MANUALS MISTAKES IN DRAWINGS MATERIALS AND WORKMANSHIP SPARE PARTS AND SPECIAL MAINTENANCE TOOLS COMPLETENESS OF EQUIPMENT INSPECTION AND TESTING AT CONTRACTOR’S PREMISES TESTS ON COMPLETION AND TRIAL RUN AT SITE TAKING OVER REJECTION OF DEFECTIVE PLANT COMPLETION CERTIFICATE & FINAL CERTIFICATE ENGINEER’S DECISION CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE PURCHASER OR THE CONTRACTOR MINTENANCE AND GUARANTEE - WARRANTY PERIOD NEGLIGENCE POWER TO VARY OR OMIT WORK SETTLEMENT OF DISPUTE TERMINATION OF CONTRACT DEDUCTION FROM CONTRACT PRICE CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING ENGINEERS
Tender Documents Commercial (Indigenous)
04 04 06 07 08 10 10 11 12 14 14 15 15 15 15 18 18 19 19 19 21 22 22 23 25 26 27 27 28 28 29 29 30
Page 2 of 56
.
34.00 ASSIGNMENT OF CONTRACT Sl. No.
30 Page No.
35.00 SUBLETTING OF CONTRACT 36.00 SUSPENSION OF WORK 37.00 FORCE MAJEURE 38.00 PROGRESS REPORT AND PHOTOGRAPHS 39.00 PATENT RIGHTS 40.00 TRAINING OF ENGINEERS 41.00 EFFECT AND JURISDICTION OF CONTRACT 42.00 TIME IS THE ESSENCE OF CONTRACT 43.00 ERECTION SUPERVISION SERVICES 44.00 ERECTION PLANT AND MATERIALS 45.00 FOREIGN PERSONNEL 46.00 DEATH, BANKRUPTCY ETC. 47.00 GRAFTS AND COMMISSION ETC. 48.00 COMPLETION OF CONTRACT 49.00 DEFENSE OF SUITS 50.00 ARBITRATION 51.00 CORRESPONDENCE 52.00 CONTRACT AGREEMENT 53.00 PAYMENTS 54.00 MISCELLANEOUS
31 31 31 32 32 32 33 33 33 35 50 50 51 51 51 51 52 53 53 55
Tender Documents Commercial (Indigenous)
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.
1.00
APPLICATION Unless otherwise provided in the Contract Agreement, these General Conditions of Contract shall govern the work of the annexed Specification.
2.00
DEFINITION OF TERMS In construing these General Conditions and the annexed Specification, the following words shall have the meanings herein assigned to them unless there is something in the subject or context in consistent with such construction.
2.01
The “Owner/Purchaser” shall mean the “National Aluminium Company Limited” , a company incorporated in India, whose Registered Office is situated at NALCO BHAVAN, P/1, Nayapalli, Bhubaneswar - 751 061.
2.02
“The Contractor” shall mean person, firm or a company whose tender has been accepted by the Purchaser and shall include his/its heirs, executors, administrators, representatives and permitted assigns.
2.03
The term Sub-Contractor used herein refers to a party or parties having a direct contract with the Contractor to whom any part of the contract has been sublet by the Contractor with the consent in writing of the Owner and shall include his heirs, executors, administrators, representatives and assigns.
2.04
The “Engineer” shall mean an officer of the owner/purchaser as may be duly appointed and authorized in writing by the purchaser to act as the Engineer on its behalf for the purpose of the contract.
2.05
The `Engineer’s Representative’ shall be the person nominated by the Engineer in writing to act on his behalf.
2.06
The term `Consultants/Consulting Engineer’ refers to consultant(s) nominated by the Engineer in writing for the contract and referred to throughout in the Contract Documents by `Consulting Engineer’ or `Consultant’.
2.07
“The Inspector” shall mean any firm or person including any employee of the owner/purchaser as may be duly appointed and authorized in writing by the owner/purchaser to inspect plant, equipment and works included by the Contractor.
2.08
`Plant’, ‘Equipment’, ‘Works’ shall mean and include plant, stores and materials to be provided and work to be done by the Contractor.
2.09
‘Contract’ means the Notice Inviting Tenders, Conditions of Tendering, and Tender Form, General Conditions of Contract, Supplementary Conditions of Contract, Technical Specifications, price
Tender Documents Commercial (Indigenous)
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.
Schedule of Prices & Quantities, Letter of Intent of Purchaser, Drawings, Subsequent amendments mutually agreed upon, and agreement to be entered under clause “Contract Agreement” of this General Condition. 2.10
The `Specification’ shall mean the Specification annexed to these General Conditions and any subsequent modifications thereof and the drawings and Schedules attached thereto (if any).
2.11
`Site’ means the lands and other places on, under, in or through which the Works are to be executed or carried out and any other lands or places provided by the Owner for the purpose of the Contract.
2.12
`Tests on Completion’ shall mean such tests as are prescribed by the Specification and/or tests mutually agreed upon by the Purchaser and the Contractor to be made by the Contractor after erection of the equipment to prove satisfactory operation as required by the Specification.
2.13
`Commissioning’ shall mean the first successful operation of the plant and equipment after all initial adjustments, trials, cleaning and reassembly required at site, if any, have been completed.
2.14
`Acceptance Tests’ shall mean such tests as are required to prove the performance guarantees of the plant given by the Contractor, before taking over of the plant by the Purchaser.
2.15
‘Initial Operation’, `Reliability Run’ or ‘Trial Operation’ shall mean continuous operation of the contract plant and materials under varying loads to furnish proof of satisfactory operation for a specified period which shall not be less than two (2) weeks.
2.16
‘Commercial Use’ shall mean that use of the equipment which the Contract contemplates or of which it is to be commercially capable.
2.17
‘Warranty Period’ shall mean the period of guarantee as explained under clause `Maintenance and Guarantee’ of these General Conditions.
2.18
‘Codes’ shall mean the applicable codes of State or Orissa as on the date of Letter of Intent and any subsequent modification thereof before the plant has been delivered.
2.19
‘Month’ shall mean calendar month.
2.20
‘Notice of Award of Contract’ / ‘Letter of Intent’/ ‘Award Letter shall mean the Purchaser’s letter / Telex conveying his acceptance of the Tender subject to such reservations as may have been stated therein.
2.21
‘Erection Supervision’ shall mean the supervision services rendered or exercised by the Contractor during the erection of the plant as explained under clause `Erection Supervision Services’ of these General Conditions.
Tender Documents Commercial (Indigenous)
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.
2.22
`Writing’ shall include any manuscript, typewritten or printed statement under or over signature or seal as the case may be.
2.23
‘Approved’, ‘Subject to Approval’, ‘Satisfactory’, ‘Equal to’ ‘Proper’, ‘As directed’, ‘Where directed’, ‘When directed’ ‘Determined by’, ‘Accepted’, `Permitted’, ‘To approval’, or words phrases of like import are used, the approval, judgment, direction, etc. is understood to be a function of Consulting Engineer or Purchaser.
2.24
Words importing `Persons’ shall include firms, companies, corporations and other bodies whether incorporated or not.
2.25
Words importing the singular only shall also include the plural and vice versa where the context requires.
2.26
‘F.O.B.’ shall mean delivery free of expenses to the Purchaser on board the vessel at the port of shipment.
2.27
‘F.O.R. Destination’ shall mean delivery free of expenses to the purchaser on rail wagons at destination Railway Station/Siding as may be named.
2.28
‘F.O.R. Works’ shall mean loaded and stowed or trimmed, free of expenses to the Purchaser on board rail wagons at the Contractor’s siding or at the nearest Railway Station for transportation.
2.29
‘Tonne’ shall mean 1000 kilogram weight, `Gallons’ shall mean imperial gallons unless mentioned specifically.
2.30
`Manufacturers’ works’ or `Contractor’s works’ shall mean the place of work used by the manufacturer, their collaborators or approved sub-contractors for the performance of the works.
2.31
Construction of Contract Terms and conditions not herein defined shall have the same meanings as are assigned to them in the Indian Sale of Goods Act (Act III of 1930) falling that in the Indian Contract Act (Act IX of 1872) and falling that in the General Clause Act 1897.
3.00
CONTRACTOR TO INFORM HIMSELF FULLY The Contractor shall be deemed to have carefully examined the General Conditions, Specification, Schedules and Drawings and also to have satisfied himself as to the nature and character of the work to be executed and, where necessary, of the site conditions and other relevant matters and details. Any information thus had or otherwise obtained from the Purchaser, Consulting Engineer or the inspector shall not in any way relieve the Contractor from his responsibility for supplying the plant and equipment and executing the work in terms of the specification including all detail and incidental works and supply of the all accessories or apparatus which may not have been
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specifically mentioned in the specification or drawings, but otherwise necessary for ensuring complete erection and safe and efficient commercial working of the plant and equipment. If he shall have any doubt as to the meaning of any portion of these General Conditions and/or specification, he shall set forth the particulars thereof and submit them to the Engineer in writing for clarification. 4.0
SCOPE OF WORK
4.01
For Manufacture, Supply & Delivery of Plant & Materials The Contractor shall design, manufacture and deliver suitably packed the plant, equipment and materials as described in the attached specification F.O.R. Works/F.O.R. Destination and, if of foreign origin, F.O.B. port of shipment, as the case may be. The Contractor shall sell and deliver the said plant, equipment and materials to the Purchaser and Purchaser shall accept the delivery of and pay for at the price agreed upon between the Purchaser and the Contractor and upon fulfillment of the terms and conditions hereinafter specified or subsequent agreed modification thereof. The Contractor shall inform the Purchaser if the plant, equipment and materials or any part thereof to be supplied under the scope of work shall be of origin and/or manufactured outside the Union of India in which case the Contractor shall give a certificate to this effect in the form required by the Purchaser. This certificate shall be called the `Certificate of Origin’. The foreign currency component for importing of plant and materials manufactured outside of India shall be specified and the estimated total C.I.F. value shall also be stated. It is clearly understood that the owner shall not give any of its import licenses for importation of these items. The Contractor shall also supply the spare parts and special tools at the quoted price and in quantities mentioned in clause `Spare Parts and Maintenance Tools’ or subsequent modifications thereof. The Contractor shall undertake that supply of necessary spare parts and special tools will be made available at any time later during the life of the plant. The price of the imported spare parts shall not be in excess of the landed cost plus a reasonable percentage towards handling charges. The price for indigenous spare parts shall be at fair market price. The Contractor shall also undertake that before going out of production of any of the spare parts, he shall give adequate advance notice to the Purchaser so that sufficient quantity of spare parts might be procured if the Purchaser so desires. Further, the Contractor shall supply the necessary drawings and specifications of these spare parts which the Contractor proposes to take off his production range to enable the Purchaser to arrange manufacture of the spa re parts by other agency.
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4.02
For Erection Supervision Services The Contractor has to supply erection supervision personnel to supervise the work of erection of the plant and equipment to be conducted even by other agencies including owner. Classification and number of personnel required shall be mutually agreed to. The services would be generally as specified in Clause `Erection Supervision Services’ hereinafter at Clause No. 43.00
4.03
For Erection of Plant & Materials The Contractor shall render complete erection services of the plant and materials supplied under the Contract if so required by the Purchaser. The services to be rendered shall be as generally described in clause `Erection of Plant and Materials’ hereinafter.
5.00
DESIGN REQUIREMENTS
5.01
All equipment and materials shall be designed and manufactured in conformance with standards stated hereinafter.
5.02
Wind Load Structures and outdoor equipment shall be designed to withstand a wind load as set forth in the latest revision of Indian Standards IS: 875 of the Indian Standards Institution.
5.03
Earthquake In general IS: 1893 shall be followed. Specific conditions/technical specification shall be referred for specific design criteria.
5.04
Safety Features The Contractor shall provide adequate guards for all couplings and other moving parts which could be considered a hazard. Safety, sentinel and relief valves are to be located or piped in such a manner as to safeguard personnel and property. All safety devices shall be in accordance with the applicable Government regulations and requirements.
5.05
Language & Measurement System All documents pertaining to the contract including specifications, schedules, notices, correspondence, operating and maintenance instructions, drawings or any other writing shall be in English language. All instruments, recorders, etc. will be calibrated in the metric (C.G.S./ M.K.S.) system of units. Details of calibration will be provided later.
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In drawings or specifications wherever both Metric and British units are indicated, the Contractor shall indicate the equipment dimensions on both the units. Location marking of all equipment shall be in Metric Units. 5.06
Accessibility Special attention shall be given to the design, arrangement and assembly of all equipments to ensure ease of maintenance and renewal of parts.
5.07
5.08
Standard Equipment & Materials and Alternates a)
Equipment, material and erection and other services shall be completed in all respects and in strict accordance with the specifications, except that alternative proposals may be submitted where stipulated provisions depart from the Contractor’s Standards, provided that the substitutions are approved as equivalent by the Engineer and the reasons therefore are stated by the Contractor in his proposal as a result of such substitution.
b)
Any request for substitution after the contract is awarded, shall be accompanied with the difference in price and such substitution can only be made on approval by the Engineer on behalf of the Purchaser in writing, provided that such substitution does not cause any addition to the contract price.
a)
All work shall be done in accordance with the applicable portions of the current editions of the codes and standards of the respective U.S.A., U.K. National and Technical Societies or equal or with the standards and codes of the Government of India, and in accordance with the applicable portions of the following codes and standards in particular: Indian Boiler Regulations Indian Electricity Act Indian Electricity Rules Indian Factories Act Indian Explosives Act Indian Standard Institution (IS) British Standard Institution (BS) American Society of Mechanical Engineers (ASME) Institute of Electrical & Electronics Engineers Inc. (IEEE)
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American Petroleum Institute (API) American Society of Testing Materials (ASTM) Hydraulic Institute National Electrical Manufacturer’s Association (NEMA) American Water Works Association (AWWA) American Standards Association (ASA) American Institute of Steel Constructions (AISC) National Board of Fire Underwriters Insulated Power Cable Engineers Association (IPCEA) All the work must be in accordance with the above mentioned codes or equivalent. b) 6.00
Where conflicts occur between any of the laws, rules, regulations, standards, and so forth, specified herein, the more stringent requirements shall govern the work.
CONTRACT PRICE The lump sum prices quoted by the Contractor in his bid with additions and deletions as may be agreed before signing of the Contract, for the entire scope of the work viz. supply and erection of equipments covered under the specification and documents shall be treated as the Contract Price.
7.0
TAXES
7.01
The Contractor shall include all taxes, duties, royalty of whatever nature, octroi, other local taxes, etc., if any, in the quoted price.
7.02
Sales tax or any other tax on material required for the work as also tax on works contract shall be payable by the Contractor and Owner will not entertain any claim whatsoever.
7.03
Notwithstanding anything contain elsewhere in the contract the Owner shall deduct at source from the payment due to the contractor the taxes as required under 13(A) of Orisaa Sales Tax Act or amended from time to time or under any other statute. The amount so deducted shall be paid by the Owner to the Sales Tax authority as per law. This is for the Contractor to deal with the Sales Tax authority directly in respect of any claim or refund relating to the above tax and Owner shall not be liable or responsible for any type of payment or reimbursement in this regard.
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7.04
All benefits of taxes duties by way of credit under CENVAT shall be passed on to the Owner/Purchaser
8.0
CONTRACT - CUM - PERFORMANCE BOND GUARANTEE FOR DUE EXECUTION OF THE CONTRACT AND PERFORMANCE DURING THE GUARANTEE PERIOD The Contractor within thirty (30) days of award of contract shall furnish a Bond by way of a bank guarantee to be kept alive till 12 months after successful completion of contract in all respects and equal to ten percent (10%) of the contract price for faithful and due fulfillment by the Contractor of all obligations under the terms and conditions of the contract and for fulfilling the terms of guarantee for a period of 12 months after successful completion. If during the contract period the bond amount gets reduced on account of any recoveries or otherwise, the contractor shall furnish a bond covering short fall to bring it to 10% of the contract value. The form of the aforesaid Bond is enclosed.
9.00
PROTECTIVE PAINTING, PACKING & MARKING The Contractor and/or Manufacturer shall properly clean and/or send blast equipment and apply an initial coat of rust inhibitor and a flat shop coat of paint (except shop finished equipment). All shop primer and paints shall be subject to approval of the Engineer. All closely machined parts shall be covered with an approved protective coating to prevent deterioration of surfaces during transportation and storage. The Contractor shall include and provide for securely protecting and packing the equipment so as to avoid damage in transit under proper conditions and he shall be responsible for all losses or damage caused or occasioned by any defect in packing. All equipments shall be packed in accordance with approved packing specifications. All equipments and parts susceptible to corrosion by exposure to moisture and all electrical equipments shall be thoroughly protected against damage during transit and storage. The Purchaser will take no responsibility for any damage done to the equipment enroute to the “site of work”, or “place of delivery” whichever may be specified due to the packing being faulty. Special packing with identification mark on packages should be provided for fragile materials. The identification marking indicating the name and address of the consignee shall be clearly marked in indelible ink on two opposite side and top of each of the packages. In addition, the Contractor shall include in the marking gross and net weights, outer dimensions and cubic measurements. Each bale or package shall be accompanied by a packing Note quoting specifically the name of the Contractor, the number and date of contract, the name of the office placing the contract and nomenclature of contents.
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Dimensions of each package shall not exceed the maximum dimensions of packages which can be accepted for transport over the `broad gauge system’ of the Railway concerned. 10.0
SHIPMENT PARTICULARS
10.01 Shipments a)
Foreign Items Responsibility of shipment of plant and equipment shall lie with the Contractor wherever the contract is for complete supply and installation or supply delivered at site basis. The Contractor shall notify the Purchaser of the date of each shipment from the port of embarkation as well as date of arrival of such shipment at designated port of arrival for information. Responsibility of cleaning the same in the port including all handling shall lie with the Contractor. Purchaser will only arrange to pay the customs duty as per information on CIF values given by the Contractor sufficiently in advance. The Contractor shall give complete shipping information concerning the weight, size, content of each package including any other information the Purchaser may require.
b)
Indigenous Item For all contracts for supply and installation or supply delivery at site basis, responsibility of all transportation from works to site shall lie with the Contractor. The Contractor shall notify the Owner of the date of each shipment from his works and the expected date of arrival at the site for information of the Purchaser. The Contractor shall also give all information concerning the weight, size and content of each packing including any other information the Purchaser may require.
c)
The Contractor shall further be responsible for all inland transportation up to site for foreign items after clearing through the port. Contractor shall also be responsible for making all necessary arrangements for loading, unloading and other handling right from his works till the site and also till the equipment is erected, tested and commissioned. He shall be solely responsible for proper storage and safe custody of all equipment.
10.02 Shipping Documents After shipment is affected following documents shall be forwarded to the Purchaser:
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a)
Foreign Items Within seven (7) days of shipment following shall be airmailed to the Purchaser for purpose of progress payment and necessary arrangement of payment of customs duty. - Application of payment in standard format of the Owner (3 copies) - Bill of Lading (5 non-negotiable copies) - Invoice including break-up for customs purposes (6 copies) - Packing list (6 copies) - Pre-dispatch clearance certificate or shipping release, if any (3 copies) - Test certificates, wherever applicable (3 copies) - Certificate of origin
b)
Indigenous items - Application for payment in standard format of Purchaser (3 copies) - Invoice (6 copies) - Packing list (6 copies) - Pre-dispatch clearance certificate or shipping Release, if any (3 copies) - Test Certificates wherever applicable (3 copies)
10.03 Demurrage, Wharfage etc. All demurrage, wharfage and other expenses incurred due to delayed clearance of the material or any other reason shall be to the account of the Contractor. 10.04 Consignee All consignment shall be addressed to and the Bill of Lading and other shipping documents shall be made in the name of the Purchaser’s Office as may be advised.
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11.0
INSURANCE
11.01 The Owner will arrange for INSURANCE of equipment and material, included under the scope of contract, to cover a)
Risk in transit by ship/air between Contractor’s port of shipment/air port and Indian port of entry.
b)
Risks in transit by rail/road during inland transportation up to the Project Site.
c)
Risks during storage and erection at the Project Site till the plant is fully commissioned under an open general insurance policy. The Owner shall intimate the name of Insurance Company and other details in due course.
11.02 The Contractor shall furnish dispatch particulars of each consignment including its value immediately to the Insurance Company. If for any delay in intimating of dispatch particulars to the Insurance Company on the part of the Contractor the claims for damages are rejected, the contractor shall be fully responsible for replacement of the damaged equipment. 11.03 The risks that are to be covered under the insurance shall include, but not limited to, the loss or damage in transit, theft, pilferage, riot, civil commotion, weather conditions, accidents of all kinds, fire, war risk, etc. The scope of such insurance shall cover the entire value of the Works from time to time. 11.04 In respect of equipment damaged in transit or during erection and commissioning, the Contractor shall replace them expeditiously and the replacement cost payable by the Owner shall be limited to the invoice of damaged equipment. In case of consignment received at the project site in outwardly sound condition of package but found shortage/damage on being opened the liability for free replacement will be accepted by the Contractor. It is the responsibility of the Contractor to lodge a claim on the Insurance Co. on behalf of the Owner. On receipt of all relevant document relating to the claim, Owner will pursue the matter with the Insurance Co. 12.00 DELIVERY Notification of delivery or dispatch in regard to each and every consignment shall be made to the Purchaser immediately after dispatch or delivery. The Contractor shall further supply to the Consignee a price invoice and packing account of all stores delivered or dispatched by him. All packages, containers, bundles and loose materials forming part of each and every consignment shall be described fully in the packing account, and full details of the contents of packages and quantity of materials shall be given to enable the Consignee to check the stores on arrival at destination.
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12.01 Passage of Risk/Ownership The title to all Indian materials, delivered by the contractor, shall pass on to the Purchaser on its being handed over to the nominated transporter. 13.00 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION (LD) If the contractor fails in the due performance of the contract to supply / erection/ testing/ commissioning the equipment within the time fixed by the contract or any extension thereof, he shall be liable at the discretion of the Engineer to the Liquidated damages and not by way of penalty amounting to one half of one percent (1/2%) of the contract price per week. The contractor’s liability for delay shall not in any case exceed ten percent (10%) of the total contract price. If the Contractor shall fail to supply the equipment or any part thereof within a reasonable period after the expiry of the appointed time or extended time as may be provided for in the contract, the provisions in Clause No. 28 “Negligence” shall become operative, in addition to the liability of L.D. as above. 14.00 IMPORT LICENCE AND FOREIGN EXCHANGE In case of supply of equipment of indigenous manufacture including any imported components, the Contractor shall arrange for necessary Import License & Foreign Exchange. In the event of Contractor requiring Actual User’s for import of equipment and/components, Purchaser shall arrange for obtaining necessary assistance in this regard. Government authorization may be required to permit the manufacture of certain equipment. The parties shall assist each other in every manner possible in securing such authorization. 15.00 CONTRACTOR’S DOCUMENTS, DRAWINGS AND INSTRUCTION MANUALS 15.01 The Contractor shall be responsible for developing detail drawings to adapt his equipment and materials to the requirement indicated in the tender specification. 15.02 Within a reasonable time not exceeding thirty days from the date of receipt Purchaser’s Letter of Intent, the Contractor shall provide the Purchaser with the following drawings and data: a)
Six (6) marked up copies of technical particulars to make them conforming to accepted proposals.
b)
Outline drawings of all equipment together with weights and sufficient overall dimensions to enable the Purchaser to design foundations and structures and associated equipment.
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c)
Drawing submission schedule indicating list of all drawings with their respective titles and dates shall be submitted to the Purchaser. The schedule shall also indicate the latest date by which Contractor shall furnish all design calculations. The schedule shall be amended or extended by the Contractor in consultation with the Purchaser as and when necessary.
15.03 Within a stipulated time period the Contractor shall submit for approval of the Purchaser the following drawings and technical data: a)
Dimensional layout drawings of the plant and equipment to be supplied under the contract and all certified data relating to the design on foundation structures to enable the Purchaser to arrange for construction of the necessary foundations and civil works. All information regarding material and size of anchor bolt, nuts, sleeves, inserts and supports which shall have to be embedded in concrete shall be furnished in the detailed foundation drawing.
b)
Dimensional drawings showing individual equipment being supplied under the contract, method and sizes of connections to the Purchaser’s other equipment, giving also the limits of variations of the dimensions.
c)
All efficiency and characteristic curves required under the specification.
d)
Schematic drawings of all wirings, connections and interlocking diagrams showing the points where the connections have to be made by the Purchaser.
e)
Necessary structural and other calculations and data required for demonstrating fully that all parts of the equipment to be furnished shall conform to the provisions and intent of the contract.
The Contractor shall submit six (6) prints of each drawing for approval. Two (2) prints shall be forwarded to the Purchaser and four (4) prints shall be forwarded to the Consulting Engineer. When prints of drawings have been marked “Approved except as noted, Resubmission required” the Contractor shall make necessary corrections and again submit corrected copies for approval as per details stipulated. Further revision will be shown by number, date and subject in a revision block. Upon receipt of the prints which have been marked “Approved” or “Approved except as noted: Forward Final drawing” the Contractor shall furnish within a reasonable time fourteen (14) additional prints of each of drawings and one (1) reproducible transparency after minor corrections, if any, to the Purchaser. Relevant civil construction drawings if felt necessary by Consulting Engineer, shall be forwarded to the Contractor in triplicate. He shall review incorporation of information furnished by him, such as,
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anchor bolt location, elevation etc. and return one certified copy each to the Purchaser and to the Consulting Engineer. Any manufacturing work in connection with the equipment prior to the approval of drawings shall be at the Contractor’s risk. The Contractor shall make any change in the designs, with prior approval of the Engineer, which are necessary to make the equipment conform to the provisions and intent of the contract, without additional cost to the Purchaser. Approval of Contractor’s drawings shall not be held to relieve the Contractor of any part of Contractor’s obligations to meet all the requirements of the contract or of the responsibility for the correctness of the Contractor’s drawings. 15.04 The details to be furnished shall include, but not restricted to the following: a)
Finals plans and layout giving complete details against the above mentioned arrangement plans including foundations plans.
b)
Assembly, sub-assembly and sectional drawings of every equipment.
c)
Complete cabling drawing giving details of cables required, terminal details, layout of trenches etc. Detailed wiring diagrams and arrangements of conduits for wiring various controls and instruments up to the required points.
d) e)
Shop drawings of all parts of equipment requiring repairing or replacements.
f)
A complete list of special erection tools and tackles required for complete assembly.
15.05 Complete spare part hand books with details and diagrams, separate recommendations shall be made for the parts required for first one year of operation of important equipment and sent to Engineer for approval. Parts requiring frequent replacement shall be listed separately from parts required for ensuring reliability in unforeseen emergencies. On finalization ten (10) set of such spare part hand books shall be furnished to the Engineer. 15.06 Assembly and erection instruction within a reasonable time after signing of the contract but at least three (3) months before starting erection the Contractor shall furnish ten (10) sets of the following for the use of Purchaser’s field Engineers: a)
Descriptive literature and drawings to illustrate the working principles, method of assembly and dismantling.
b)
Instruction book for proper erection and assembly of all equipment and necessary instructions for checking and recording proper assembly of the plant.
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Erection schedule giving the sequence of erection with reference to package/ assembly/ sub-assembly identification. c)
Instruction sheets for proper balancing, alignment, adjustment, checking and calibrations as may be necessary.
15.07 All drawings and technical data are to be furnished in English language only. 15.08 Final Drawings and Operation Maintenance Manuals Before completion of the work, the Contractor shall furnish fourteen (14) complete sets of prints and one (1) reproducible transparency of all detailed drawings of the equipment actually supplied and as erected and assembled at site. In addition ten (10) sets of comprehensive manuals for use in the operation and maintenance of the plant shall be supplied at least six (6) months before the actual commissioning date to the Engineer. 15.09 Seven (7) copies of monthly fabrication progress report for all equipment and material shall be supplied to the Engineer. 16.00 MISTAKES IN DRAWINGS The Contractor shall be responsible for and shall pay for any alterations of the work due to any discrepancies, errors or omissions in the drawings or other particulars supplied by him whether such drawings or particulars have been approved by the Engineer or not. If any dimensions figured upon a drawing or a plan differ from those obtained by scaling the drawing or plan the dimensions as figured upon the drawing or plan shall be taken as correct. 17.00 MATERIALS AND WORKMANSHIP All materials used in the manufacture of the equipment shall be selected from the best available for the purpose, considering strength, durability and best engineering practice. Liberal factors of safety shall be used through out the design and specially in the design of all parts subject to alternating stresses or shocks. All the work shall be performed and completed in a thorough workmanship like manner and shall follow the best modern practice in the manufacture of high grade equipment notwithstanding any omissions in the specifications. Castings shall be free from holes, flaws, cracks or other defects and shall be smooth, close grained and of true forms and dimensions. No plugged or filled up holes or other defects will ordinarily be allowed. Such castings are liable to be rejected. However, the Contractor may rectify minor casting defects by welding or other method in accordance with the standard manufacturing practice provided such rectification does not affect the
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strength of the casting or impair the efficient working of the plant and prior approval of the Purchaser is obtained for the same. 18.00 SPARE PARTS AND SPECIAL MAINTENANCE TOOLS 18.01 The spare parts as required for the equipment under supply are listed in respective specification. The list is not exhaustive but only indicative. The Contractor shall also supply list of Guaranteed Spares for two years normal operation indicating parts name, catalogue no., quantity and unit prices on project site delivery basis. If any short fall is noticed during 2 years from the date of commissioning the same shall be supplied free of cost by the Contractor. 18.02 In case of machinery and plant, the Contractor shall include provision for such tools as he recommends to be absolutely essential for proper maintenance and repair of the plant. A detailed list of the tools along with the itemized prices shall be submitted along with the tender. In the absence of this list, the tender is liable to be rejected. One new set of all special tools for maintenance for each type of equipment shall be furnished by the Contractor at his own expense and shall be dispatched along with the equipment. 18.03 The contractor shall also undertake that supplies of necessary maintenance equipment and spare parts will be made available for the life of the plant offered through his Agents on a continuous basis at reasonable price. 19.00 COMPLETENESS OF EQUIPMENT The equipment shall be complete in every respect with all mountings, fixtures and standard accessories which are normally supplied even though not specifically detailed in the specification. The Contractor shall not be eligible for any extra payment in respect of such mountings, fittings, fixtures and accessories which are needed for safe operation of the equipment as required by applicable codes of the country though they may not have been included in the contract. All similar component parts of similar equipment supplied shall be interchangeable with one another. The various equipment supplied under this contract shall be subject to the Purchaser’s approval 20.00 INSPECTION AND TESTING AT CONTRACTOR’S PREMISES The Engineer and his duly authorized representative shall have at all reasonable times access to the Contractor’s /Sub-contractor’s premises of works, and shall have the power at all reasonable times to inspect drawings of any portion of the work or examine the materials and workmanship of the plant during its manufacture there and if part of the plant is being manufactured on other
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premises, the Contractor shall obtain for the Engineer and his duly authorized representative permission to inspect as if the plant is manufactured on the Contractor’s premises. The Engineer shall on giving seven (7) days notice in writing to the Contractor setting out any grounds of objections which he may have in respect of the work, be at liberty to reject any drawings & all or any part of workmanship if the subject of any of the said grounds of objection, which in his opinion are not in accordance with the contract. The Contractor shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the Engineer giving therein that no modifications are necessary to comply with the contract. The Contractor shall give the Engineer and his duly authorized representatives notice of any material being ready for testing and the Engineer or the said representative shall (unless the inspection of tests is voluntarily waived), on giving twenty four (24) hours previous notice in writing to the Contractor, attend at the Contractor’s premises (as the case may be) within fifteen (15) days of the date on which the material is notified as being ready failing which visit, the Contractor may proceed with the tests which shall be deemed to have been made in the Engineer’s presence. All standard shop tests, physical and chemical tests required by the Standards or as may be prescribed or approved by the Engineer shall be conducted by the Contractor. The Engineer reserves the right to waive any of the above test requirement and to prescribe new test required if found necessary to expedite the work or to conform to the latest and best practice. Definitions, methods of measurement, calibration of instruments and required procedure as referred in the above standard and/or those approved by the Engineer as equivalent shall be followed. The Contractor shall forthwith forward to the Engineer duly certified copies of the test certificates in quadruplicate (one copy to the Purchaser and three copies to the consulting Engineer) for approval. Further ten (10) copies of the shop test certificate shall be bound with the instruction manuals referred to in clause “Contractor’s documents, drawings and instruction manuals”. In all cases where contract provides for tests, whether at the premises or works of the Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide free of charge to the Purchaser, such labor, materials, electricity, fuel, water, stores, apparatus and instruments as may reasonably be demanded to carry out efficiently such tests of the plant, in accordance with the contract and shall give facilities to the Engineer or his authorized representative to accomplish such testing. When the tests have been satisfactorily completed in the Contractor/Sub-contractor’s Works, the Engineer shall issue a certificate to that effect within fifteen (15) days after completion of test, but if the tests were not witnessed by the Engineer or his representative the certificate would be issued within fifteen (15) days of the receipt of the test certificates by the Engineer. No plant shall be transported before such a certificate has been issued. The satisfactory completion of these tests or the issue of this certificate shall not bind the Purchaser to accept the plant should it on further tests after erection, be found not to comply with the contract provisions.
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21.00 TESTS ON COMPLETION AND TRIAL RUN AT SITE Where possible all tests shall be carried out before dispatch. Should, however, it become necessary for the final tests as to performance and guarantees to be held over until the plant is erected at site, they shall be carried out as per agreed procedure within two (2) months or such time as may be considered reasonable by the Purchaser after commissioning of the equipment. Inspection and test at site during erection and on completion of erection shall be carried out on any plant and equipment to satisfy the guaranteed performance of each equipment and the whole installation as set forth below: Individual equipment tests: (I)
Inspection and checking of units
(II)
Placing in operation
(II)
Initial operation
(IV)
Reliability tests
(V)
Efficiency and consumption tests
(VI)
Load tests
The sequence of tests for individual equipment shall be as mutually agreed to between the Contractor and the Engineer. Duration of the trial operation of the complete equipment shall be 30 continuous days with available wagon rakes during this period as mutually agreed and decided. The acceptance test shall be carried out within two (2) months after the trial run has been satisfactorily completed. Any delay for carrying out these works for force majeure reasons shall be given due consideration. Should the result of these tests not come within the margin specified, the test shall, if required, be repeated after necessary rectification measures recommended by the Contractor within one (1) month from the date of plant is ready for retest, and the Contractor shall repay to the Purchaser all reasonable expenses which he may be put to by such tests. The performance and acceptance tests of the complete installation shall be carried out to prove the guarantees specified for different equipment. These tests shall be made in accordance with established and approved procedures. The Contractor shall submit within reasonable time after the award of contract, detailed procedure for conductance of all tests for approval of the Engineer. The procedure shall include the following information for such test:
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(I)
Loads at which tests will be conducted.
(II)
Time and durations of each test.
(II)
Instrument locations shown by a schematic diagram for each test. (Calibration certificates for each instrument shall be furnished before commencement of test).
(IV)
All formulas, calculations, conversion factors, correction curves, etc. to be used for test conductance.
(V)
Sample test report forms, and data sheet that will be used to record test results and valuation of final results.
On completion of all tests, the overall efficiency of the plant shall be determined in accordance with the procedure mutually agreed upon between the Contractor and the Engineer unless otherwise covered under the Standards and Specification. In all cases, where the contract provides for test at the site, the Purchaser, except where otherwise specified, shall provide, free of charge, such labor, materials, fuel, water, electricity, lubricants as may be required from time to time and as may reasonably be demanded to carry out such tests of the plant, material or workmanship in accordance with the contract. Any special apparatus and precision instruments required for site test shall be provided by the Contractor. If for any reason, other than the fault of the contractor performance and acceptance tests for any unit shall not be carried out within sixty (60) days of notice by the Contractor to the Purchaser of the unit being ready for tests, then the Purchaser will issue an acceptance certificate on the last day of such period and payments due to the Contractor on acceptance shall be made, but nevertheless the Contractor, shall if called upon to do so by the Purchaser, within a period twelve (12) months from the said last date, make the said tests on the same terms as provided in the contract. 22.00 TAKING OVER Upon successful completion of all the tests to be performed at site on equipment and systems furnished and erected by the Contractor, the Engineer shall Issue to the Contractor a taking over certificate as a proof of the final acceptance of the equipment. Such certificate shall not relieve the Contractor of any of his obligations which otherwise survive by terms and conditions of the contract after issuance of such certificate. 23.00 REJECTION OF DEFECTIVE PLANT If the completed plant or any portion thereof, it is taken over under the clause ‘Taking Over’, be found defective or fails to fulfill the requirements of the contract, the Engineer shall give the Contractor notice selling forth particulars of such defects or failure, and the Contractor shall forth
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wile make the defective plant good or to make it comply with the requirements of the contract. Should he fail to do so within a reasonable time, the Purchaser may reject and, replace at the cost of the Contractor the whole or any portion of the plant as the case may be, which is defective or fails to fulfill the requirements of the Contract. Such replacement shall be carried out by the Purchaser within a reasonable time and at a reasonable price, and where reasonably possible to the same specification and under comparative condition. The Contractor’s full and extreme liability under the clause shall be satisfied by the payment to the purchaser of the original contract price including charges of erection and/or supervision of erection plus the difference if any between the replacement price of the equipment including charges for erection and /or supervision of erection and the original contract price including charges for erection and / or supervision of erection in respect of such defective plant. In the event of such rejection, the Purchaser shall have the right to operate any and all equipment as soon as and as long as it is in operating condition, whether or not, such equipment has been accepted as complete and satisfactory, to enable him to obtain necessary replacement, except that this shall not be construed to permit operation of any equipment which may become damaged by such operation before any required alternations or repairs and/or replacement have been made. All repairs or alternations or replacement required of the Contractor shall be made by the Contractor at such times as directed and in such manner as will cause the minimum interruption in the use of the equipment by the Purchaser. Should the Purchaser not so replace the rejected plant within a reasonable time, the Contractor’s full and extreme liability under his clause will be satisfied by the repayment of all money paid by the Purchaser to him in respect of such plant. Nothing in this clause shall be deemed to deprive the Purchaser or affect any rights under the contract which he may otherwise have in respect of such defects or deficiencies or in any way relieve the Contractor of his obligations under the contract. 24.00 COMPLETION CERTIFICATE & FINAL CERTIFICATE 24.01 Application for Completion Certificate When the contractor fulfils his obligation under the contract he shall be eligible to apply for completion certificate in respect of the work by submitting the completion documents along with such application for completion certificate. The owner or his representative shall normally issue to the Contractor the completion certificate within one month after receiving an application from the Contractor after verifying from the completion documents and satisfying himself that the work has been completed in accordance with and as set out in the construction and erection drawings, and the contract documents. The contractor, after obtaining the completion certificate, is eligible to present the final bill for the work executed by him under the terms of contract.
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24.02 Completion Certificate Within one month of the completion of work in all respects the Contractor, shall be furnished with a certificate by the owner or his representative of such completion but no completion certificate shall be give nor shall the work be deemed to have been executed until all scaffoldings surplus material and rubbish is cleared off the site completely nor until the work shall have been measured by the Engineer, whose measurement shall be binding and conclusive. The work will not be considered as complete and taken over by the Owner, until all the temporary works, labor and staff colonies etc. constructed are removed and work site cleared to the satisfaction of the Engineer. If the Contractor shall fall to comply with the requirements of this clause on or before the date fixed for the completion of the work, the Engineer may at the expenses of the Contractor remove such scaffoldings, surplus materials and rubbish and dispose off the same as he thinks fit and clean off such dirt as aforesaid, and the Contractor shall forthwith pay the amount of all expenses so incurred and shall have not claim in respect of any such scaffolding or surplus materials as aforesaid except for any sum actually realized by the sale thereof. Completion Certificate shall be in 3 parts as follows: 1) 2) 3)
Physical/Mechanical completion work. Satisfactory completion of commissioning of equipment with load. Satisfactory completion of guarantee.
The Contractor shall clearly indicate the 3 dates separately. 24.03 Completion Documents For the purpose of clause 24, the following documents will be deemed to form the completion documents: (i) The technical documents according to which the work was carried out. (ii)
Three sets of construction drawings showing therein the modification and corrections made during the course of execution and signed by the Engineer.
(ii)
Completion Certificate for embedded and ‘Covered-up’ works.
(iv)
Certificates of final levels as set out for various works.
(v)
Certificates of test performed for various works.
(vi)
Materials appropriation statement for the materials issued by the owner for the works and list of surplus materials returned to the owner’s store duly supported by necessary documents.
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(vi)
Physical / Mechanical completion work.
(viii)
Satisfactory completion of commissioning of equipments with load.
(ix)
Satisfactory completion of guarantee.
The contractor shall clearly indicate the 3 dates separately. 24.04 Final Decision and Final Certificate Upon the expiration of the period of liability and subject to the Engineer being satisfied that the works have been duly maintained by the Contractors during monsoon or such period as herein provided in clause 8.00 and that the Contractor has in all respect duly made up all subsidence and performed all his obligations under the contract, the Engineer shall (without prejudice to the right of the Owner to retain the provision of relevant clause hereof) otherwise give a certificate, herein referred to as the final certificate, to that effect and the Contractor shall not be considered to have fulfilled the whole of his obligations under the contract until Final Certificate shall have been given by the Engineer not withstanding any previous entry upon the work and taking possession, working or using of the same or any part thereof by the Owner. 24.05 Certificate and Payments No Evidence of Completion Except the final certificate, no other certificates or payment against a certificate or on general account shall be taken to be an admission by the Owner of the due performance of the Contract or any part thereof or of occupancy or validity of any claim by the Contractor. 25.00 ENGINEER’S DECISION In respect of all matters which are left to the decision of the Engineer the Engineer shall, if so required to do so by the Contractor give in writing a decision there on to the Contractor. All decisions of the Engineer shall be binding on the Contract. 26.00 CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE PURCHASER OR THE CONTRACTOR No Certificate of the Engineer on account, nor any sum paid on account by the Purchaser, nor any extension of time for the execution of the works by the Contractor shall affect or prejudice the rights of the Purchaser against the Contractor or relieve the Contractor of his obligations of the materials supplied and no certificate shall create liability for the Purchaser to pay for alterations, amendments, variations of additional work, not ordered in writing by the Engineer or discharge the liability of the Contractor for payment of damages, whether due, ascertained or certified or not to any sum against the payment of which he is bound to Indemnify the Purchaser, nor shall any such certificate nor the acceptance by him or any sum paid on account or otherwise, affect or prejudice the rights of the Contractor against the Purchaser.
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27.00 MAINTENANCE AND GUARANTEE – WARRANTY PERIOD The Contractor shall guarantee in respect of the plant and materials to be furnished by him the following: (a)
All equipment shall be free from any defect due to faulty design, materials and/or workmanship.
(b)
The equipment shall operate satisfactorily and the performance and efficiencies of the equipments shall not be less than the respective guaranteed values.
(c)
The efficiencies, temperature rises and other performance data furnished for the equipment.
The guarantees have to be furnished on forms approved by the Engineer and shall be signed by the Contractor and / or his sub-contractor. If the Contractor finds, after his tender is accepted, that a variation in work, construction technique or the quality of materials is necessary to fulfill the guarantees called for, such variations may be made with the approval of the Engineer, provided the request for changes is made before signing the contract the changes are to be made without any increase in the contract price. The above guarantees shall be valid for a period of twelve (12) calendar months commencing immediately on the satisfactory completion of the final tests at site or thirty six (36) months after the last consignment to complete the plant is received at site,, whichever may be earlier. This period of the guarantee shall be called the ‘Warranty period’. During this period, the contractor’s liability shall be limited to the replacement of any defective parts that may develop in plant of his own manufacture of those of his sub-contractor’s under the conditions provided for by the contract under proper use and arising solely from faulty design, materials or workmanship provided always that such defective parts as are not repairable at site, and are not essential in the meantime in the commercial use of the plant, are promptly returned to the Contractors Works unless otherwise arranged. All such replacements of defective parts mentioned above shall be made free of costs at site by the Contractor and the return of the defective parts to the Contractor’s works shall be the Contractor’s responsibility and shall be made at his expense. The Purchaser will, however, render such assistance in this matter as well expedite the same. In the case of defective parts not repairable at site but essential in the meantime for the commercial use of the plant, the Contractor shall replace at site free of cost to the Purchaser the said defective parts before the defective parts are removed to his Works. If for rectification or replacement of any part of equipment or work due to defective materials, manufacture or design, the services of the Contractor personnel are requisitioned within the guarantee period, these services shall be made available free of any cost to the Purchaser.
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If it becomes necessary for the contractor to replace or renew any defective portions of the plant under this clause, the provisions of this clause will apply to the portions of the plants so replaced or renewed until the expiration of six (6) months from the date of such replacement or renewal or until the end of the above mentioned period of twelve (12) months, whichever may be later. If any defect be not remedied within a reasonable time, the Purchaser may proceed to do the work at the Contractor’s risk and expenses but without prejudice to any other rights which the Purchaser may have against the Contractor in respect of such defects. If the replacement or renewals are of such character as may affect the efficiency of the plant, the Purchaser shall have the right to give the Contractor within one month of such replacement or renewal, notice in writing that ‘tests’ on completion be made in which case such tests be carriedout as provided in clause “tests a completion” and trial run at site hereof. Should such test show that the plant sustains the guarantee given in the Contract; the cost of the tests will be borne by the Purchaser. Should the guarantee be not sustained, the cost of the test shall be borne by the Contractor. All replacement or renewals to be carried out by contractor during the maintenance period shall be subject to such clauses of these general conditions as may be considered reasonable by the Engineer. Until the final certificate has been issued, the Contractor shall have the right of entry, at his own risk and expenses by himself or his duly authorized representatives whose names shall previously have been communicated in writing to the Engineer, at all reasonable working hours upon all necessary parts of the works, for the purpose of inspecting the working and the records of the plant and taking notes there from and, if he desires, at his own expense making any tests, subject to the approval of the Engineer that work will not be unreasonably withheld. The issue of the Engineer’s Certificate referred to in clause ‘Certificate of Engineer’ shall in no way expect the contractor from the provision of this clause. At the end of the maintenance period, the liability ceases. In respect of goods not covered by the first paragraph of this clause, the Purchaser shall be entitled to the benefit of any guarantee given to the Contractor by the original supplier or manufacturer of such goods. 28.00 NEGLIGENCE If the Contractor neglects to execute the work with due diligence and expedition or refuses or neglect to comply with any reasonable orders given to him in writing by the Engineer in connection with the work, or contravene the provisions of the contract, the Purchaser may give notice in writing to the Contractor calling upon him to make good the failure, neglect or contravention complained or should the Contractor fail to comply with such notice within a period considered reasonable by the Purchaser from the date of service thereof, in the case of failure, neglect or contravention capable of being made good within that time or otherwise within such time as may in the opinion or the Purchaser be reasonably necessary for making it good, then and in such case the Purchaser shall
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have the option and be at liberty to take the work wholly or in part, out of the Contractor’s hand and may carry on the work envisaged in the contract at a price with any other person or persons to execute the same or any part thereof and provide any other materials, tools, tackle or labor for the purpose of completing the works or part thereof. In such event the Purchaser shall without being responsible to the Contractor for fair wear and tear of the same be entitled to seize and take possession and have free use of all materials, tools, tackle or other things which may be on the site, for use at any time in connection with the work to the exclusion of any right of the Contractor over the same and the Purchaser shall be entitled to retain and apply and balance sum which may otherwise be then due on the contract by him to the Contractor or such part thereof as may be necessary, to the payment of the cost of execution of such work as aforesaid. If the cost of executing the work as aforesaid shall exceed the balance due to the Contractor and the Contractor fails to make good the deficit, the said materials, tools, tackle, construction plant or other things, the property of the Contractor as may not have been used up in the completion of the works, may be sold by the Purchaser and the proceeds applied towards the payment of such difference and the cost of an incidental to such sale. Any outstanding balance existing after crediting the proceeds of such sale shall be paid by the Contractor on the certificate of the Engineer. But when all expenses cost and charges incurred in the completion of the work are paid by the Contractor, all such materials, tools, tackle, construction plant or other things not used up in the completion of the works and remaining unsold shall be removed by the Contractor. If the proceeds of the above sale of the Contractor’s materials, tools, tackle, construction plant etc. are insufficient to cover the executing the aforesaid work, the balance remaining after crediting the proceeds of such sale shall be recoverable from the Contractor by encashing the Bank Guarantee/available/ any other money payable by Purchaser or by action of law. Not withstanding anything contained above, the Purchaser may determine the contract due to any breach or failure of the Contractor, without notice before determining the contract as above, if in the opinion of the Purchaser, the default or defaults committed by the Contractor is/are curable and can be cured by the Contractor if an opportunity is given to him, then the owner may issue a notice in writing calling upon the Contractor to cure the default within such time as may be specified in the notice. In the event of termination, the security deposit will be forfeited without reference to the Contractor and if no amount is available towards Security Deposit, an identical amount is recoverable from the contractor. 29.00 POWER TO VARY OR OMIT WORK No alternations, amendments, omissions, additions, suspensions or variations of the work hereinafter referred to as ‘Variations’, under the contract shall be made by the Contractor except as directed in writing by the Engineer, but the Engineer shall have full power, subject to the provision hereinafter contained from time to time during the execution of the contract by notice in writing, to instruct the Contractor to make such variation without prejudice to the contract and the Contractor
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shall carry out such variation and be bound by the same conditions as far as applicable, as though the said variation occurred in the contract. If any suggested variations would, in the opinion of the Contractor, if carried out prevent him from fulfilling any of his obligations or guarantees under the contract, he shall notify the Engineer thereof within 10 days in writing and the Engineer shall decide forthwith whether or not the same shall be carried out and if the Engineer confirms his instructions, the contractor’s obligations and guarantees shall be modified to such and extent as may be justified. In the absence of any such notification, the Contractor shall be bound to carry out the suggested variations without any additional financial implication to Purchaser and it will amount to an absolute waiver of any claim whatsoever. 30.00 SETTLEMENT OF DISPUTE 30.01 Except as otherwise specifically provided in the Contract all disputes concerning question of fact arising under the Contract s hall be decided by the Engineer subject to a written appeal by the Contractor to the Engineer, whose decision shall be final to the parties hereto. 30.02 Any disputes or differences including those considered as such by only one of the parties arising out of or in connection with the Contract shall be to the extent possible settled amicably between the parties. 30.03 If amicable settlement can not be reached then unresolved disputed issues may be settled by arbitration as provided subsequently. 31.00 TERMINATION OF CONTRACT Notwithstanding anything contained elsewhere in this contract, if at any time during the term of this contract the plans of the Government of India and/ or the State Government change for any reason, the Purchaser shall have the right to terminate the Contract by notice to the Contractor by a registered letter. In respect of such changes the material that is complete as ready for transportation within thirty (30) days after such notice, Purchaser agrees to accept delivery thereof at the contract price and terms. In the case of the remainder of the undeliverable material, the Purchaser may elect (a) to have any part thereof completed and take delivery thereof at the contract price and (b) to cancel the residue (if any) and pay to the Contractor aprorated amount of the contract price based upon the state of completion to be certified by him. The Contractor shall deliver all such material in process of manufacture to the Purchaser and shall return to the Purchaser any funds remaining to the Purchaser’s credit. No payment shall be made by the Purchaser for any material not yet in process of manufacture on the date of notice of cancellation is received. 32.00 DEDUCTION FROM CONTRACT PRICE All costs, damages or expenses which the Purchaser may have paid, for which under the contract Contractor is liable, may be deducted by the Purchaser from any money due or be coming due by
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him to the Contractor under the contract, or may be recovered by action of law or otherwise from the Contractor. Further all legal and statutory deductions will be made and the Contractor is not entitled to any reimbursement or claim what-so-ever except only a tax deduction certificate. In the event of recovery to the necessary extent becoming impossible owing to insufficiency of the performance bond and withheld amounts, the balance due to the purchaser, may be recovered in any way the Purchaser may deem fit. 33.00 CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING ENGINEERS The Contractor shall agree to co-operate with the Purchaser’s other contractors and Consulting Engineers for associated equipment and freely exchange with them such technical Information as is necessary to obtain the most efficient and economical design and to avoid unnecessary duplication of equipment. No remuneration shall be claimed from the Purchaser for such technical cooperation. The Purchaser and consulting Engineer shall be provided with two (2) copies each of all correspondence addressed by the Contractor to other Contractors in respect to such exchange of technical information. If any part of the Contractor’s work depends for proper execution or results upon the work of any other Contractor, the Contractor shall inspect and promptly report in writing to the engineer any defects; in such works that render it unsuitable for such proper execution and results. His failure to so inspect and report shall constitute an acceptance of the other Contractor’s work as fit and proper for the reception of his work, except as to defects which may develop in the other Contractor’s work after the proper execution of his work. 34.00 ASSIGNMENT OF CONTRACT Any assignment of the contract or any part thereof or any rights or obligations there under, by the Contractor without the prior written consent of the Purchaser shall be void. The purchaser shall be at liberty to transfer and assign the contract only to Government Company as defined in the Indian Companies Act-I of 1956, and such Company shall exercise all the rights and be liable for all obligations of the Purchaser contained herein in the same manner as if the agreement had been entered into between the said Company and the Purchaser. The purchaser shall be also at liberty to entrust the carrying out of the agreement only to a Government Institution and upon the Instructions of the purchaser, the Contractor undertakes to do all things necessary to carry out of his obligations under the agreement with such institution as may be entrusted by the purchaser as agent or otherwise. The Purchaser, however, shall not be in either case relieved or discharged from any of his obligations and liabilities under the contract. The contractors shall be advised in writing of the date of any such substitution.
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35.0
SUBLETING OF CONTRACT The Contractor shall not without the consent in writing of the Purchaser, which shall not be unreasonably withheld, assign or sublet his contract or any substantial part thereof other than for raw materials, for minor details, or for any part of the works of which the makers are named in the contract, provided that any such consent shall not relieve the Contractor from any obligation, duty or responsibility under the contract. For components/equipments procured by the Contractors for the purpose of the Contract; after obtaining the written approval of the Owner, the Contractor’s purchase specifications and enquiries shall call for quality plans to be submitted by the suppliers along with their proposals. The quality plans called for from the vendors shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the Vendor’s quality control organization, the relevant reference documents/standards used, acceptance level, inspection of documentation raised, etc. Such quality plans of the successful vendors shall be discussed and finalized in consultation with the Engineer and shall form a part of the purchase order/contract between the Contractor and the vendor. Within 3 weeks of the release of the same purchase order/contracts for such bought out items/components, a copy of the same without price details but together with detailed purchase specifications, quality plants and delivery conditions shall be furnished to the Engineer by the Contractor.
36.00 SUSPENSION OF WORK The owner reserves the right to suspend and reinstate execution of the whole or any part of the works without invalidating the provisions of the contract. Orders for suspension or reinstatement of the works will be issued by the Engineer to the Contractor in writing. The time for completion of the works will be extended for a period equal to duration of the suspensions. Any necessary and demonstrable costs incurred by the contractors as a result of such suspension of works other than force majeure conditions will be paid by the owner, provided such costs are substantiated to the satisfaction of the Engineer. The owner shall not be responsible for any liabilities if suspension or delay is due to some default on the part of the Contractor or his sub- Contractor. 37.00 FORCE MAJEURE 37.01 Any delays in or failure of the performance of either parties thereto shall not constitute default here under or give rise to any claims for damages, if any, to the extent such delays or failure of performance caused by occurrences such as acts of God or the public enemy, expropriation or confiscation of facilities by Government authority, compliance with any order or request of any Government authorities, act of war rebellion, sabotage, fire, floods, explosions, riots or illegal strikes, provided always that such occurrence result in impossibility of performances of the contract. 37.02 Only events of Force Majeure which impedes the execution of the contract at the time of its occurrence shall be taken into cognizance.
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38.00 PROGRESS REPORTS AND PHOTOGRAPHS The Contractor shall furnish six (6) prints each of progress reports and photographs of the work done in his shop. Photographs shall be taken when the where indicated by the Engineer or his representative. Photographs shall be approximately 100 mm x 125 mm in size including a margin of 5 mm side of fixing. Adequate number of photographs shall be submitted indicating various stages of manufacture. Each photograph shall contain the date the name of the Contractor and the title of the view taken. Monthly progress reports shall be submitted. These shall detail the status of design, procurement of raw materials and manufacture of the equipment. The Engineer shall advise the Contractor about the number of copies of progress schedule and photographs he has to submit each month together with the names and address of persons to whom they are to be sent. 39.00 PATENT RIGHTS Royalties and fees for patents covering materials, articles, apparatus devices, equipment and processes used in the plant and equipment shall be deem to have been included in the Contract Price. The Contractor shall defend any claims which alleged in a suit or proceeding against the Purchaser that the equipment or any part thereof constitutes an infringement of any patent, it notified promptly in writing and given authority, Information and assistance for the defense and the Contractor shall pay all damages and costs awarded against the Purchaser in such suit or proceeding for the patent infringement. In case the equipment in such suit or proceeding is held to constitute infringement and the use of the equipment or part is prohibited, the Contractor shall, at his own expenses, either procure for the Purchaser the right to continue using the equipment or replace same with a non-infringing equipment or modify it so it become non-infringing or remove the equipment and refund the purchase price plus the transportation and installation costs thereof. The foregoing states entire liability of the Contractor for patent infringement and the Purchaser shall be kept indemnified in this regard. Notwithstanding any dispute regarding patents Purchaser will have a right to the use of materials, articles, apparatus, devices, equipment and process till final adjudication of such dispute. 40.00 TRAINING OF ENGINEERS It so desired by the Purchaser, the Contractor shall undertake to train Engineers to be nominated by the Purchaser in the manufacture, testing, erection and operation of similar equipment as covered by the contract. The period of training, number of engineers to be trained, program of training will be mutually agreed upon. Cost of to and fro traveling for each engineer to the manufacturer’s factory and their living expenses shall be borne by the Purchaser.
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41.00 EFFECT & JURISDICTION OF CONTRACT 41.01 The contract shall be considered as having come into force from the date of the acceptance of Letter of Intent. 41.02 The laws applicable to this contract shall be in the laws in force in India. The courts of Orissa shall have exclusive jurisdiction in all matters arising under the contract. 42.00 TIME IS THE ESSENCE OF CONTRACT 42.01 The time and the date of completion of the works as stipulated in the contractor’s proposal and accepted by the owner without or with modifications, if any, and so incorporated in the Letter of Intent, shall be deemed to be the essence of the contract. The Contract shall so organize his resources and perform his work as to complete it not later than the date agreed to. 42.02 The Contractor shall submit a detailed PERT Network within the time frame agreed above covering various key phases of the works such as design, procurement, manufacturing, shipment and field erection activities within thirty (30) days after the date of Letter of Intent. This network shall also indicate the interface facilities to be provided by the Owner and the dates by which such facilities are needed. Contractor shall discuss the network so submitted with the owner. The agreed network which may be in the form as submitted or in revised form in line with the outcome of discussions shall form part of the Contract to be signed within sixty (60) days from the date of acceptance of Letter of Intent. During the performance of the contract, if in the opinion of the Engineer proper progress is not maintained suitable changes shall be made in the contractor’s operations to ensure proper progress. 42.03 The above PERT network shall be reviewed and periodic review reports shall be submitted by the Contractor as directed by the Engineer. 42.04 Within a month of the award of the contract, the Contractor shall make available to the Engineer, a detailed manufacturing programme, in line with the agreed contract network. Such manufacturing program shall be reviewed, updated and submitted to the Engineer once every two months thereafter. 43.00 ERECTION SUPERVISION SERVICES The Contractor, if required by the Purchaser, shall furnish the services of one or more supervisors, to render technical advice, assistance and guidance to the Purchaser in connection with the erection and/or commissioning of equipment subject to the provisions herein after set forth. In case of complete erection of plant and materials such services shall automatically be included in the scope of the Contractor and no extra charges shall be applicable.
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The Purchaser; shall pay the Contractor for the service of each supervisor as follows: (a)
As agreed rate; per-calendar day from the date on which supervisor leave his headquarters up to and including the date of his return thereto. This rate is based up on a normal 48 hours work-week of six (6) eight-hour workdays, Monday through Saturday. Sunday will be normally a holiday but any other day of the week may be made a normal holiday depending upon working conditions.
(b)
The Purchaser shall in addition to the charge specified in paragraph above, pay the Contractor for any overtime work authorized by the Purchaser and performed by the supervisor at an agreed overtime rate per hour for hours worked in excess of 8 hours per day and all hours worked on the seventh day. There will be no overtime charge for work performed on locally recognized or national holiday or time spent in traveling to and from the supervisors headquarters.
(c)
Hours during which the supervisor is ready, willing and able to work up to 48 hours per week shall be regarded as having actually been worked by him even though his services are not in fact utilized.
The Purchaser shall secure any labor permit or any other authorization which may be required to permit the Erection Supervisor to perform the services and any loss of the supervisor’s services pending the procurement of any such permit or authorization shall be to the Purchaser’s account and shall be paid for by the Purchaser. The Purchaser shall furnish, at his own expenses, and assume responsibility for all labor and labor supervision and shall make available all necessary installation to tools, except such special tools as may be supplied by the Contractor pursuant to written agreement between the parties. The supervisor may elect to bring certain personal tools which tools are to remain his property at all times. The Purchaser shall assist the Supervisor in arranging entry and exit permit for such tools. If any portion of the work of supervision by the Contractor proves to be defective within one (1) year from the date of completion of supervision, the Contractor, if promptly notified thereof in writing, will at his own expense, and at his option, with make repairs or supply replacement parts directly to or for the equipment and necessary to correct any defect or defects in such equipment directly resulting from such defective work of supervision on the part of the Contractor and will at his own expenses, furnish the necessary supervision for such corrections. The contractors liability in connection with his furnishing a supervisor hereunder shall in no event exceed the cost of correcting any such defective work of supervision in the manner herein provided and upon the expiration of the said one (1) year, all such liability shall terminate. In no event shall the Contractor be liable for special, indirect or consequential damages. The Contractor shall not be liable for loss of damage due to delays in furnishing the services or in the work resulting form any cause beyond the Contractor’s reasonable control including compliance with any Government regulations, orders or instructions, acts of God, acts of omission
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of Purchaser, acts of civil or military authority, fires, strikes, war earthquake, storm, volcanic eruptions, landslide, riot or delays in transportation. The Purchaser shall advise the Contractor in writing reasonably in advance of the date that the supervisor shall be required to start performance of the services. 44.00 ERECTION OF PLANT AND MATERIALS 44.01 General Unless otherwise mutually agreed to the provisions of this clause shall apply where the services for erection of plant & material supplied by the contractor are included in the scope of work. If so desired by the Purchaser, the Contractor shall receive the imported equipment, if any, at the port of entry, clear them through Customs and make damage report through port broker. The Contractor shall arrange for payment at prescribed rate of Customs Duty which will be reimbursed by the Purchaser against Contractor’s valid documents. The Contractor shall transport all imported equipment from port of entry to the site and unload all Imported/Indigenous equipment at site. Escort service shall be provided, if necessary and called for. All storage at port of entry or at railway station will be at Contractor’s charge. The Contractor shall be responsible for complete installation of the equipment start-up and testing at site. All equipment and tools for transportation and erection shall be provided by the Contractor. All materials and /or equipment, after receipt at site, shall be checked and verified against shipping documents and all claims against loss or damage in transit shall be intimated to the purchaser. The materials and/or equipment shall remain under the custody of the Contractor until the plant as a whole is taken over by the Purchaser upon completion of the work. The Contractor shall take adequate steps to ensure safety of such materials and / or equipment. Necessary stores receipt certificates shall be issued to the Purchaser after the stores are checked and certified. No materials and/or equipment pertaining to the Contract shall be removed from site without the consent in writing of the Purchaser. The Contractor shall be responsible for obtaining the correct reference lines for purposes of fixing the alignment of various equipment. 44.02 Regulation of Local Authorities and Statues The Contractor shall comply with the rules and regulations of local authorities during the performance of his field activities. He shall also comply with the minimum wages Act, 1948 and the payment of wages act (both of the Government of India) and the rules made there under in respect of any employee or workmen employed or engaged by him or his sub-Contractor.
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All registration and statutory inspection fees, if any, in respect of his work pursuant to this contract shall be to the account of the Contractor. However, any registration, statutory inspection fees lawfully payable under the provisions of the Indian Boiler Regulations and any other statutory laws and its amendments from time to time during erection in respect of the plant equipment ultimately to be owned by the Purchaser, shall be to the account of the Purchaser. Should any such inspection or registration need to be re-arranged due to the fault of the Contractor or his subContractor, the additional fees of such inspection and/or registration shall be borne by the Contractor. 44.03 Work at Site In the execution of work, no persons other than the Contractor or his appointed representative, sub-Contractor and workmen shall be allowed to do work at site, except by the special permission in writing of the Engineer or his representative, but access to the Works at all times shall be accorded to the Engineer and his representative and other authorized officials or representatives of the Purchaser. Nevertheless, the Contractor shall not object to the execution of work by other Contractors or tradesmen whose names shall have been previously communicated in writing to the Contractor by the Engineer and afford them every facility for the execution of their several works simultaneously with his own. The Contractor shall at all times provide sufficient fencing, notice boards, lights and watchmen to protect and warn the public and guard the works, and in default thereof the Purchaser may provided such fencing, notice boards, lights and watchmen as he may deem necessary and charge the cost thereof to the Contractor. The work so far as it is carried out on the Purchaser’s premises shall be carried out at such time as the Purchaser may approve and so as not to interfere unnecessarily with the conduct of the Purchaser’s business but the Purchaser shall give the Contractor all reasonable facilities for carrying out the work. No female labor shall be employed during dark hours. The Contractor shall not employ for the purpose of the contract any person who is below the age of eighteen years and shall pay to each laborer, for the work done by such laborer, wages not less then the wages paid for similar work in the neighborhood. The Engineer shall have the right to enquire into and decide any complaint alleging that the wages paid by the Contractor to any laborer for the work done by such laborer is less than the wages paid for similar work in the neighborhood, and to refuse appointment of labor less than eighteen years of age. The Contractor shall make regular and prompt payment of wages to the laborers engaged on the work and in not case the payment shall be delayed more than seven (7) days following the period for which the wages are due. If it is found the workers are not paid regularly the contract is liable to be rescinded. The Contractor shall comply strictly with the provisions of Labor Laws in this behalf.
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44.04 Manufacturer’s Supervision The Contractor may be required to work under the supervision of the manufacturer’s Engineers, where the Contractor is not the manufacturer. However, this will not relieve the Contractor of his responsibility of the correctness of quality of workmanship. 44.05 Engineer’s Supervision All the works shall be carried out under the direction and to the satisfaction of the Engineer. The Contractor shall be responsible for the correctness of the positions, levels and dimensions of the works according to the drawings, notwithstanding that he may have been assisted by the Engineer in setting out the same. 44.06 Contractor’s Representative The Contractor shall employ at least one competent representative, whose name or names shall have previously been communicated in writing to the Engineer by the Contractor for approval to superintend the erection of the plant and carrying our of the work. The said representative, or if more than one be employed, one of the representative, shall be present at the site, during working hours, and any written orders or instructions which the Engineer or his authorized representative may give to the said representative of the Contractor, shall be deemed to have been given to the Contractor. The Engineer shall be at liberty to object to any representative or person employed by the Contractor in the execution of or otherwise of the work who shall misconduct himself or be incompetent, or negligent, and Contractor shall remove the person so objected to, upon receipt from the Engineer or notice in writing requiring him to do so and shall provide; in his place a competent representative at the Contractor’s expenses. The Contractor’s representatives to be employed for the purpose of the work at site shall be made available when the Purchaser shall inform the Contractor in writing to the effect. The services of the Contractor’s representative shall be made available for such period as the Engineer may require and they shall work at all reasonable times as may be necessary to complete the work within the period specified in the Contract. 44.07 Program of work and Progress Reports The Contractor shall submit at such times as may be required by the Engineer, schedules showing the program and order in which the Contractor proposes to carry out the work, with dates and estimated completion times of various parts of the work. Such schedules shall be approved by the Engineer, prior to starting the erection. Such times shall be binding on the Contractor for purpose of assessing the penalty as called for under subsequent clause. The Engineer may not allow the Contractor to start work for non-submission of the time schedule of the erection program.
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During the progress of work the Contractor shall submit monthly progress reports and photographs and such other reports on the erection work and organization, as the Engineer may direct. The progress indicated be arrived by agreement between the Contractor and the Engineer. The Contractor shall also submit an anticipated one (1) month progress schedule at the beginning of each month describing in detail the anticipated progress for the following month. The Contractor shall also submit every week a list of various categories of men working under him. Monthly progress reports shall be submitted within the tenth day of the month following the reporting month. 44.08 Man - Power Report The Contractor shall submit to Engineer, on the first day of every month, a man hour schedule for the month, detailing the man hours scheduled for the month, skill wise and are wise. The Contractor shall also submit to the Engineer on the first day of every month, a man power report of the previous month detailing the number of persons scheduled to have been employed and actually employed, skill wise and the areas of employment of such labor. 44.09 Extension of Time The application for extension of time is to be given to owner/purchaser through the Engineer and the owner/purchase may authorize extension of time after considering the due merits. Whenever extension of time is granted by the owner/purchaser, the same shall be on the existing terms and conditions of the contract and without any additional financial liability to the Owner. The Contractor in any case shall have no claim whatsoever for any type of compensation on account of any delay attributable to any one. 44.10 Liability for Accident and Damage The Contractor shall Indemnify the Purchaser against any claims which may be made under the workman’s Compensation Act, 1923, or any statutory modification thereof or otherwise for or in respect of any damages or compensation payable in consequence of any accident or injury sustained by any workman or other person whether in the employment of the Contractor or not. In every case in which by virtue of the provisions of sub-section (1) of Section 12 of the Workman’s compensation Act, 1923, the Purchaser is obliged to pay compensation to a workman employed by the Contractor in execution of the works, the Purchaser will recover from the Contractor the amount of the compensation so paid and without prejudice to the rights of the Purchaser under sub-section (2) of Section 12 of the said Act. The Purchaser shall be at liberty to recover such amount or any part thereof by deducting it from the Performance Bond or from any sum due by the Purchaser to the Contractor whether under the contract or otherwise. The Purchaser shall not be bound to contest any claim made against it under Section 12, subsection (1) of the said Act, except on the written request of the Contractor and upon his giving to the Purchaser full security for all costs for which the Purchaser might become liable in consequence of contesting such claim. In the event of claim being made or action brought against
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the Purchaser involving the Contractor and arising out of the matters referred to and in respect of which the Contractor is liable under this clause, the Contractor shall be immediately notified thereof and he shall with the assistance, if so required by the Purchaser, but at the sole expense of the Contractor, conduct all negotiations for the settlement of the same, or of any litigation that may arise there from. In such case the Purchaser, at the expenses of the Contractor, afford all available assistance for any such purpose. The Contractor shall be responsible for all loss, damage or depreciation to the plant until the plant is taken over in accordance with clause ‘Taking Over’. The Contractor shall, during the progress other work, properly cover up and protect the plant from injury by exposure to weather and; shall take every reasonable, proper, timely and useful precaution against accident or injury to the same from any cause shall be and remain answerable and liable for all accidents or injuries thereto which, until the same be or be deemed to be taken over under clause ‘Taking Over’ may arise or be occasioned by the acts or omissions or the Contractor of his workmen or sub- Contractors, and all losses and damage to the Plant arising from such accidents or injuries as aforesaid shall be made good in the most complete and substantial manner by and at the sole cost of the Contractor and to the reasonable satisfaction of the Engineer. Until the plant shall be or deemed to be taken over as aforesaid the Contractor shall also be liable for and shall be deemed to have agreed to indemnity the Purchaser in respect of all damage to any property of the Purchaser or of others occasioned by the negligence or fault of the Contractor or sub-contractor or his or their workmen or representatives or by defective design, work or material or otherwise. The Contractor shall pay all taxes due in India for the personnel employed by the Contractor work arising out of their services in connection with the contract and obtaining at his (Contractor’s) own cost ‘work permits’ from competent authorities to enable any foreign personnel to work in India. The Contractor shall be responsible for all formalities in connection with the passport, obtaining of visas, police permits, and expenses for customs duties related to personal goods of foreign personnel to be employed in the erection work. However, the Purchaser shall If requested, assist the Contractor in obtaining visas and “work permits’ for the foreign personnel to be deputed for the erection work. 44.11 Cleanliness During erection, the Contractor shall, without any additional payment, at all times keep the working and storage areas used by him free from accumulation of waste materials or rubbish. If the Contractor fails to remove the rubbish, within forty eight (48) hours, after being requested by the Engineer, the rubbish will be removed by others and cost back charged to the Contractor. Any inflammable material should be removed forthwith on request by the Engineer.
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Before completion of erection, the Contractor shall remove or dispose of in a satisfactory manner all temporary structures, packing cases, waste and debris and leave the premises in a condition satisfactory to the Engineer. Similarly the labor colony, the offices and the residential areas of the Contractor’s employees and workmen shall be kept clean & neat to the entire satisfaction of the Engineer. Proper sanitary arrangements shall be provided by the Contractor, in the work areas office and residential areas of the Contractors. 44.12 Co-ordination with the Purchaser’s Engineers The Contractor shall at all times work in co-ordination with the Purchaser’s Engineers and afford them every facility to become familiar with the erection and maintenance of the equipment. In respect of observance of local rules, administrative matters, co-ordination with other Contractors and the like, the Contractor and his personnel shall work under the Purchaser’s Engineer in charge of the work. 44.13 Work and Services to be provided by the Purchaser Unless otherwise agreed upon, the following works and services shall be provided by the Purchaser for carrying out complete erection work: (a)
Water Supply Water supply for construction purpose will be provided by the Purchaser at one mutually agreed point at site. Drinking water will also be made available at one central point at site. The Contractor shall make his own arrangement for any further distribution. Such distribution pipe network shall have the prior approval of the Engineer at site so as not to interfere with the layout and progress of other construction works. The water supply shall be free of cost. Contractor shall ensure that there is no wastage of water. On completion of the work, the Contractor shall remove all such work and shall reinstate and make good any work disturbed to the satisfaction of the Engineer.
(b)
Power Supply (I)
Electric power will be supplied at 400/440 V and shall be metered and charged at applicable rates.
(II)
Supply for execution of work will be made available at one point only. This point will not be more than 500 meters away from the Contractor’s premises. The Contractor shall make his own arrangement at his own cost for distribution of
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power to different worksites. This arrangement shall however, be coordinated and laid with approval of the Engineer. Any change in the alignment of the Contractor’s distribution lines necessitated by his work or another work must be done at Contractor’s cost. The Engineer also reserves the right to change the location of point of supply whether necessitated by his work or another work and the Contractor shall make his own arrangement at his own cost for extending his distribution line to the new location of supply point. A 3 phase armored cable shall be used by the Contractor for connecting their equipment to Purchaser’s point supply. (III)
The Purchaser shall not however, guarantee the supply of electricity and no compensation for any failure or short supply of electricity will be entertained and this does not relieve the Contractor of his responsibility for timely completion of the work as stipulated in the Contract.
(IV)
It shall be the responsibility of the Contractor to provide and maintain the complete installation on the load site of the supply with due regard to safety requirement at site. All cabling, equipment, installations etc. shall comply in all respects with the latest statutory requirements and safety provisions, i.e. as per given in the Central/State Electricity Acts and Rules etc. The Contractor will ensure that his equipment and Electricity wiring etc. are installed, modified and maintained by a licensed Electrician / Supervisor and before power is supplied, a test certificate is to be produced to the Engineer for his approval.
(V)
At all times, IEA Regulations shall be followed failing which the Purchaser has a right to disconnect the power supply without any reference to the Contractor. No claim shall be entertained for such disconnection by the Engineer. Power supply will be reconnected only after production of fresh certificate from authorized electrical supervisors. The Purchaser will not liable for any loss or damage to the Contractor’s equipment as a result of variation in voltage or frequency or interruption of power supply or other loss to the Contractor arising there from.
(VI)
(VII)
The Contractor shall ensure that the Electrical equipment installed by him are such that average power factor does not fall below 0.9 at this premises. In case P.F. falls below 0.9 in any month, he will reimburse to the purchaser at the rate same as OSEB’s rate for per unit fall of P.F. determined from time to time by Purchaser all units consumed during the month.
(VIII)
The power supply required for Contractor’s colony near the plant site will be determined by the Purchaser and shall be provided as per State Electricity Board’s Rules and other Statutory provisions applicable for such installations from time to time. In case of power supply to Contractor’s colony, the power will be made available at a single point and the Contractor shall make his own arrangement at
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his own cost for distribution to the occupants of the colony as per Electricity Rules & Acts. The site area and colony shall be sufficiently lighted to avoid accidents. (IX)
The Contractor will have to provide and install his own light and power meters which will be governed as per Central/State Govt. Electricity Rules. The meters shall be sealed by the Purchaser.
(X)
In case of damage to any of the Purchaser’s equipment on account of fault, intentional or unintentional on the part of the Contractor, the purchaser reserves the right to recover the cost of such damage from the contractor’s bill.
(XI)
After completion of work, the Contractor shall promptly dismantle, at his own cost distribution and other facilities that he may have erected and shall also remove the same within a reasonable time fixed by the Engineer and on his failure to do so the Purchaser will be entitled to realize from his reasonable compensation fixed by the Engineer and also to remove them at the cost of the Contractor.
(XII)
Only motors up to 3HP will be allowed to be started direct on line. For motors above 3 HP and up to 100 HP suitable starting devices approved by the Purchaser Engineer, shall be provided by the Contractor. For Motors above 100 HP slip ring induction motors with suitable starting devices as approved by the Engineer shall be provided by the Contractor.
(XIII)
The single line distribution system with loadings and specifications shall be submitted to the Engineer for his approval before the system is installed. The system shall conform to Central/State Statutory provisions Act, with latest amendments and to the Approved specifications of the company. The installations have to be inspected and approved by the Electrical Inspector, Govt. of Orissa before energisation. The total requirement of power shall be indicated by the tenderer in his tender and confirmed within thirty days from the date of Letter of Intent.
(XIV) (d)
Land for Contractor’s Use (I)
The Purchaser will at his own discretion and convenience and for the duration of the execution of the work make available near the site, land for construction of Contractor’s field office, godowns, workshops and assembly yard required for the execution of the contract. The Contractor shall at his own cost construct all these temporary buildings and provide suitable water supply and sanitary arrangement approved by the Engineer.
(II)
On completion of the works undertaken by the Contractor, he shall remove all temporary works erected by him and have the site cleared as directed by Engineer. If the Contractor fails to comply with these requirements, the Engineer at
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the expenses of the Contractor will remove such surplus and rubbish materials and dispose off the same as he deems fit and get the site cleared as aforesaid, and the contractor shall forthwith pay the amount of all expenses so incurred and shall have no claim in respect of any such surplus materials disposed off as aforesaid. But the Purchaser reserves the right to ask the Contractor any time during the pendency of the contract to vacate the land by giving 7 days notice on security reasons on national interest or otherwise. A token rent of Rs. 100/(Rupees one hundred only) per hectare or part thereof per annum or part thereof shall be charged for the land so occupied. (III)
Land for residential accommodation for staff and labor will be made available at the discretion of the Engineer and rent for the same will be as decided by the Engineer according to location and area taken by the Contractor.
(e)
Electricity and drinking water at normal charges for labor quarters at a central point within the land provided by the Purchaser. The cost of distribution, if any, shall be borne by the Contractor.
(f)
Assistance to the Contractor in obtaining Indian visas, residential or working permits for the permits for the personnel, if necessary.
(g)
Water and electricity as may be required for the initial starting up of the equipment free of charge to Contractor.
(h)
Necessary Engineers, operators and other personnel for start – up commissioning and acceptance tests of the equipment free of charge to Contractor.
(i) (J)
Assistance in obtaining priorities for transportation, customs permit etc. Suitable access to site and possession of the site shall be afforded to the Contractor by the Purchaser.
44.14 Work and Services to be provided by the Contractor Unless otherwise agreed upon, the following work and services shall also be provided under the erection contract. (i)
Clearing, unloading the equipment from the rail or road transport to Contractor’s transport/vehicle and delivery the same to storage area. Demurrage charges, if incurred at rail head or at site for default of the Contractor shall be paid by him
(ii)
Opening of packing cases, Inspection and checking of materials. Repair and replacement of contract material damaged or lost in transit or at site.
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(iii)
Final adjustment of foundation levels by chipping and dressing, checking location, elevation etc. of anchor bolts and grouting or anchor bolts and base plates.
(iv)
Complete erection of the equipment covered under the contract, final preparation for testing, commissioning, final run and acceptance tests and putting the plant into commercial operation.
(v)
All consumable stores required for the above work, except those mentioned under Clause 44.13 (i).
(vi)
Watch and ward to ensure security and safety of materials under the custody.
(vii)
Furnishing of residential accommodation to erection labor and other personnel.
(viii)
Daily transport for his erection personnel to and fro between residence and site.
(ix)
All erection tools and lifting tackles, also all equipment, tools and tackles for transportation of all equipment to site. A list of such tools and tackle and equipment shall be submitted to the purchaser before commencement of site work. These tools and tackle shall not be removed from the site without written permission of the Engineer.
(x)
All ladders, platforms, temporary supports and facilities required for handing of heavy packages at site required for erection.
(xi)
Necessary clerical staff, supervisory personnel skilled and unskilled labor.
(xii)
Third Party Insurance at site and insurance of Contractor’s personnel employed at site as required under Workmen’s Compensation Act.
(xiii)
Site offices and covered storage as required.
(xiv)
Postage, telephone and telegraph expenses.
(xv)
Cleaning up of site during and after erection.
(xvi)
Applying final paint to all equipment, piping, hanger etc. covered under the contract.
(xvii)
Necessary supervisory personnel with approved license as per provisions of Indian Electricity rules.
(xviii)
If the Contractor uses his own crane, he must have a skilled crane operator.
(xix)
Contractor must take all safety precautions during work and the workmen must use safety belts, tested gloves, masks and other devices as necessary for safety of personnel
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(xx)
Contractor should provide identity badges for his employees. These should be properly displayed during working hours.
(xxi)
The Contractor shall employ only competent and skilled workmen fully experienced and capable of performing duties assigned for them. When local laws required the employee shall be required to acquire certificate of competency for his work from the competent authority.
(xxii)
Communication The Contractor will make his own arrangement for all his communications needs such as telephone, telex etc. at his site office and his residential area. Purchaser will assist in getting the above facilities, in case he finds and difficulty.
(xxiii)
First – Aid The Contractor shall provide necessary first-aid facilities for all his employees, representatives and workmen working at site. Enough number of contractor’s personnel shall be trained in administering first-aid.
(xxiv)
Welfare facilities Contractor shall provide in his labor colony all necessary standard welfare facilities like canteen, shopping facility etc.
44.15 Lines and Grades All the works shall be performed to the lines/alignments, grades and elevations indicated on the drawing. The Contractor shall be responsible to locate and layout the works area. Basic horizontal and vertical control points will be established and marked by the Engineer at site at suitable points. These points shall be used as datum/reference points for the works under the contract. The Contractor shall inform the Engineer well in advance of the times and places at which he wishes to do work in the area allotted to him, so that suitable datum reference points may be established and checked by the Engineer to enable the Contractor to proceed with his works. Any work done without being properly located may be removed and/or dismantled by the Engineer at Contractor’s expenses. 44.16 Fire Protection
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(a)
The work procedures that are to be used during the erection shall be those which minimize fire hazards to the extent practicable. Combustible materials, combustible waste and rubbish shall be collected and removed from the site at least once each day. Fuels, oil and volatile or flammable materials shall be stored away from the construction and equipment and materials storage area in safe containers. Adequate precaution shall be taken in handling and storage of flammable gas. Care shall be taken to avoid and reduce hazards from electrical short circuits and faults. Untreated canvas paper, plastic or other flammable flexible materials shall not at all be used at site for any other purpose unless otherwise specified. If any such materials are received with the equipment at the site, the same shall be removed and replaced with acceptable material before moving into the construction area of storage.
(b)
Similar corrugated paper fabricated cartons etc. will not be permitted in the construction area either for storage or for handling of materials. All such materials used shall be of water proof and flame resistant type. All the other materials such as working drawings plans etc. which are combustible but are essential for the works to be executed shall be protected against combustible resulting from welding sparks, cutting flames and other similar fire sources.
(c)
All the Contractor’s supervisory personnel and sufficient number of workers shall be trained for fire - fighting and shall be assigned specific fire protection duties. Enough of such trained personnel must be available at site during the entire period of the Contract.
(d)
The contractor shall provide enough fire protection equipment of the types and number for the ware - houses, office, temporary structures, labor colony area etc. Access to such fire protection equipments shall be easy & kept open at all times.
44.17 Materials Handling & Storages (a)
All the equipments furnished under the Contract and arriving at site shall be promptly received, unloaded and transported and stored in the storage spaces by the contractor.
(b)
The Contractor shall be responsible for examining all the shipment and notify the engineer immediately of any damages, shortages; discrepancy etc. for the purpose of Engineer’s information only. The Contractor shall submit to the Engineer every week a report detailing all the receipts during the week. However, the Contractor shall be solely responsible for any shortages or damage in transit, handling and/ or storage & erection of the equipment at site. Any demurrage, wharfage and other charges claimed by the transporters, railways etc. shall be to the account of Contractor.
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(c)
The Contractor shall maintain an accurate & exhaustive record detailing out the list of all equipment received by him for the purpose of erection & keep such record open for the inspection of the Engineer at any time.
(d)
All equipments shall be handled very carefully to prevent any damages or loss. No bare wire, rope, slings etc. shall be used for unloading and/ or handling of the equipment without the specific written permission of the Engineer. The equipment stored shall be properly protected to prevent damages either to the equipment or to the floor where they are stored. The equipment from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such equipment at site.
(e)
All electrical panels, control gear, motors and such other devices shall be properly dried by heating before they are installed and energised. Motor bearings, slip rings, commutators and other exposed parts shall be protected against moisture ingress and corrosion during storage and periodically inspected. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent corrosion due to prolonged storage.
(f)
All the electrical equipment such as motors, generators, etc. shall be tested for insulation resistance at least once in three months from the date of receipt till the date of commissioning and a record of such measured insulation values maintained by the Contractor. Such records shall be open for inspection by the Engineer.
(g)
The Contractor shall ensure that all the packing materials and protection devices used for the various equipment during transit and storage are removed before the equipment are installed.
(h)
The consumables and other supplies likely to deteriorate to storage must be thoroughly protected and stored in a suitable manner to prevent damage or deterioration in quality by storage.
(i)
All the materials stored in the open or dusty location must be covered with suitable weatherproof and flame-proof covering material wherever applicable.
(j)
If the materials belonging to the Contractor are stored in areas other than those earmarked for him the Engineer will have the right to get it moved to the area earmarked for the Contractor at the Contractor’s cost.
(k)
The Contractor shall be responsible for making suitable indoor storage facilities to store all equipment which required indoor storage. Normally, all the electrical equipment such as motors, control gear, generators, exciters and consumables like electrodes, lubricants etc. shall be stored in the closed storage space. The Engineer, in addition, may direct the Contractor to move certain other materials which in his opinion will require indoor storage areas which the Contractor shall strictly comply with.
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44.18 Construction Management (a)
The field activities of the Contractors working at site will be coordinated by the Engineer and the Engineer’s decision shall be final in resolving any disputes or conflicts between the contractors and tradesmen of the Purchaser regarding scheduling and co-ordination of work. Such decision by the Engineer shall not be a cause for extra compensation or extension of time for the Contractor.
(b)
The Engineer shall hold weekly meetings of all the Contractors working at site, at a time and a place to be designated by the Engineer. The Contractor shall attend such meetings and take notes of discussions during the meeting and the decisions of the Engineer and shall strictly adhere to those decisions in performing his works. In addition to the above weekly meetings, the Engineer may call for other meetings either with individual contractors or with selected number of contractors and in such a case the Contractor, if called, will also attend such meetings.
(c)
Time is the essence of the Contract and Contractor shall be responsible for performance of his woks in accordance with the specified construction schedule. If at anytime, the Contractor is falling behind the schedule, he shall take necessary action to make good for such delays by increasing his work to comply with the schedule and shall communicate such actions in writing to the Engineer, satisfying that his action will compensate for the delay. The Contractor shall note be allowed any extra compensation for such action.
(d)
The Engineer shall however not be responsible for provision of additional labor and/ or materials or supply or any other services to the Contractor except for the co-ordination work between various entities as set out earlier.
44.19 Safety Regulations (a)
Without prejudice to the general obligation under the statutes the Contractor shall ensure the safety of all the workmen, materials and equipment either belonging to his or to others working at site.
b)
The Contractor will notify the Engineer of his intention to bring on to site any equipment or any container, with liquid or gaseous fuel or other substance which may create hazard. The Engineer shall have the right to prescribe the conditions under which such equipment or container may be handled and used during the performance of the works and the Contractor shall strictly adhere to such instructions. The Engineer shall have the right to inspect any construction plant and to forbid its use, if in his opinion it is unsafe. No claim due to such prohibition shall be entertained by the Purchaser.
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c)
Where it is necessary to provide and / or store petroleum products or petroleum mixtures and explosives, the Contractor shall be responsible for carrying out such provision and / or storage in accordance with the rules and regulations laid down in Petroleum Act, 1934, Explosive Act 1948 published by the Chief Inspector of Explosives of India. All such storage shall have prior approvals of the Engineer. In case any approvals are necessary from the Chief Inspector of Explosives or any statutory authorities, the Contractor shall be responsible for obtaining the same.
d)
The Contractor shall be responsible for provisions of all safety notices and safety equipment required both by the relevant legislations and the Engineer as he may deem necessary.
e)
The Contractor shall be responsible for the safe storage of his and his sub - contractor’s radioactive sources, if any.
f)
In no circumstances will the Contractor interfere with fuses and electrical equipment belonging to the Purchaser or other Contractors.
g)
Before the Contractor connects any electrical appliances to and plug or socket belonging to the other Contractor or Purchaser, he shall -
h)
i)
Satisfy the Engineer that the appliance is in good working condition;
ii)
Inform the engineer of the maximum current rating, voltage and phases of the appliances;
iii)
Obtain permission of the Engineer detailing the sockets to which the appliances may be connected.
The Engineer will not grant permission to connect until he is satisfied that i) The appliance is in good condition and fitting with a suitable plug; ii)
The appliance is fitting with a suitable cable having two earth conductors, one of which shall be an earthed metal sheath surrounding the cores.
i)
No electric cable in use by the Contractor/Purchaser will be distributed without prior permission. No weight of any description will be imposed on any such cable and no ladder or similar equipment will rest against or he attached to it.
j)
No work shall be carried out on any live equipment. The equipment must be made safe by the Engineer and permit - to - work issued before any work is carried out.
k)
The Contactor employs the necessary number of qualified, full time electricians to maintain his temporary electrical installation.
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45.00 FOREIGN PERSONNEL 45.01 The Contractor shall submit to the purchaser data on all personnel he proposes to bring into India for the performance of the works under the contract at least sixty (60) days prior to their departure to India. Such data will include for each person the name, his present address, his assignment and responsibility in connection with the works, and a short resume of his qualification, experience etc. in relation to work to be performed by him. 45.02 Any person unsuitable and unacceptable by the purchaser shall not be brought to India. Any person brought to India, if found unsuitable or unacceptable by the purchaser, the Contractor shall within a reasonable time make alternative arrangements for providing a suitable replacement and repatriation of such unsuitable personnel. 45.03 No person brought to India for the purposes of the works shall be repatriated without any consent of the purchaser in writing, based on a written request from the Contractor for such repatriation giving reasons for such an action to the Engineer. The purchaser may give permission for such repatriation that the progress of work will not suffer due to such repatriation. 45.04 The Contractor and his expatriate personnel shall respect all India Acts, Laws, rules and regulations and shall not in any way interfere with Indian political and religious affairs and shall conform to any other rules and regulations the Government of India, the purchaser and the Engineer may establish from time to time, on them. The Contractor expatriate personnel shall work and living in close coordination and coordination with their co workers and the community and shall not engage themselves in any other employment either part - time or full - time nor shall they take part in any local politics. 45.05 The purchaser shall assist the Contractor, to the extent possible in obtaining necessary permits to travel to India and back by issue of necessary certificates and other information needed by the Government agencies. 46.00 DEATH, BANKRUPTCY ETC. If the Contractor shall die or dissolve or commit any act of bankruptcy or being a Corporation, commence to be wound up except for reconstruction purposes or carry on its business under a receiver, the executors, successors or other representatives in law of the estate of the Contractor or any such receiver, liquidator or any person in whom the contract may become vested, shall forthwith give notice thereof in writing to the purchaser and shall for one month, during which he shall take all reasonable steps to prevent a stoppage of the work, have the option of carrying out the contract subject of the approval of Purchaser and subject to his or their providing such guarantee as may be required by the Purchaser but not exceeding the value of works for the time being remaining unexecuted, provided however that nothing above said shall be deemed to relieve the Contractor or his successors of his or their obligations under the contract under any
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circumstances. In the event of stoppage of the works the period of the option under this clause shall be fourteen (14) days only, provided that should be above option be not exercised, the contract may be terminated by the purchaser by notice in writing and the same power and provisions reserved to the Purchaser in clause `Negligence’ in the event of taking the work out of the Contractor’s hands shall immediately become operative. 47.00 GRAFTS AND COMMISSION ETC. Any graft, commission, gift or advantage given promised or offered by or on behalf of the Contractor or his partner, agent, officers, director, employee or servant or any one on his or their behalf in relation to the obtaining or to the execution of this or any other contract with purchaser, shall in addition to any criminal liability which it may incur, subject the contractor to the cancellation of this and other contracts and also to payment of any loss or damage to the purchaser resulting from any cancellation. The purchaser shall then be entitled to deduct the amounts so payable from any money otherwise due to the Contractor under the contract. 48.00 COMPLETION OF CONTRACT Unless otherwise terminated under the provisions of any other relevant clause, this contract shall be deemed to have been completed all the expiration of the guarantee period as provided for under the clause entitled `Guarantee Period’ as provided for under the clause entitled `Guarantee’ and only on issue of a certificate to that effect and not otherwise. 49.00 DEFENCE OF SUITS In any action in court is brought against the purchaser or Engineer or an officer or agent of the purchaser, for the failure or neglect on the part of the contractor to perform any acts, matters, convenants or things under the contract, or for damage or injury caused by the alleged omission or negligence on the part of the Contractor, his agents, representatives or his sub-contractors, workmen, suppliers, or employees, the Contractor shall in all such cases indemnify and keep the purchaser, and the Engineer and / or his representative harmless from all losses, damages, expenses or decrees arising of such action. 50.00 ARBITRATION All disputes or differences arising under the contract whether during or after completion of the contractor or whether before or after determination, for closure or breach of the contract (other than those in respect of which the decision of any person is by the contract expressed to the final and binding) shall after written notice by either party to the contract to the other of them and to the Appointing Authority hereinafter mentioned be referred for adjudication to a sole Arbitrator to be appointed as hereinafter provided.
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For the purpose of appointing the sole Arbitrator referred to above, the CMD NALCO who shall be Appointing Authority will send within thirty days of receipt of the notice to the Contractor a panel of three names of persons. The Contractor shall on receipt of the names as referred select any one of the person names to be appointed as a sole Arbitrator and communicate his name to the Appointing authority within thirty days of receipt of the names. The Appointing Authority shall there upon appoint the said person as the sole Arbitrator. If the Contractor fails to communicate such selection as provided above within the period specified, the Appointing Authority shall make the selection and appoint the selected person as the Sole Arbitrator. If the Arbitrator so appointed is unable to / unwilling to act or resigns his appointment or vacates his office due to any reason whatsoever sole arbitrator or shall be appointed as aforesaid. The work under the contract shall not be stopped during the arbitration proceedings. The Arbitrator shall be deemed to have entered on the reference on the date he issues notices to both the parties fixing the date of first hearing. The Arbitrator may, from time to time, with the consent of the parties, enlarge the time for making and publishing the awards. The Arbitrator shall give a separate award in respect of each dis pute or difference and shall give a reasoned and speaking award / awards. The venue of arbitration shall be at Bhubaneswar. However, if the situation so warrants, it may as and when required, he held at the place where the site of work is situated. The fees, if any, of the Arbitrator shall, if required to be paid before award is made and published, be paid half and half by each of the parties. The cost of the reference and of the award including the fees, if any, of the Arbitrator shall be in the discretion of the Arbitrator who may direct to and by whom and in what manner, such costs or any part thereof shall be paid and may fix or settle the amount of costs to be so paid. The award of the arbitrator shall be final and binding on both the parties. Subject to aforesaid the provisions of the Arbitration Act 1940 or any statutory modification or reenactment thereof and the rules made there under, and for the time being in force, shall apply to the arbitration proceeding under this clause. For Public Sector Enterprises guidelines as per circular of BPE No. 15.9.86 - BPE (FIN) dtd. 30.03.1989 as amended from time to time will be applicable for resolving any disputes. 51.00 CORRESPONDENCE The Purchaser shall ordinarily correspond with the Contractor at the address furnished by the Contractor.
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The Contractor shall ordinarily forward two (2) copies of all correspondence relating to this contract to the Purchaser and two (2) copies to the Consulting Engineer or his representative as may be requested. Two (2) copies of all correspondence from the Contractor to Purchaser’s other Contractors for associated plants shall be forwarded to the Purchaser and the Consulting Engineer. All drawings and correspondence to the Purchaser and the Consulting Engineer shall be transmitted by the Contractor via Air Mail or alternatively by means involving the minimum time of transit. 52.00 CONTRACT AGREEMENT If so desired by the Purchaser, a formal Agreement shall be entered into by the Contractor with the Purchaser for the proper fulfillment of the Contract. The expenses of completing and stamping the Agreement shall be paid by the Contractor, and the Purchaser shall be furnished free of charge with an executed stamped counterpart of the Agreement as also copies of the Agreement as may be required by the purchaser. Any tender drawing, technical data and / or correspondence which forms the basis of an order or a contract aforesaid, or which may be furnished by the Contractor for the Purchaser’s approval or information as provided under the said order or contract, shall be in English and it is in any other language, a complete translation in English shall have to be duly furnished. The Purchaser shall not be bound to consider any tender drawing, technical data or correspondence which is not furnished in English.
53.00 PAYMENTS 53.01 The payment to the Contractor for the performance of the works under the contract will be made by the purchaser as per the guidelines and conditions specified herein. All payments made during the contract shall be on account of payments only. The final payment will be made on completion of all the works and on fulfillment by the Contractor of all his liabilities under the contract. 53.02 Currency of Payment The payments for the foreign currency potion of the contract price will be made in the currency of the bid. If the bid is in a currency other than that of the country of origin of goods, payment may be made in an amount equivalent to the bid price in the currency of the country of origin. The Indian Rupees portion of contract price stated in the contractor’s bid will be paid in Indian Rupees. 53.03 Payment Schedule
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The Contractor shall prepare and submit to the Engineer for approval, break-up of the contract price. The contract price break-up shall be interlinked with the agreed detailed PERT Network of the Contractor setting forth his starting and completion dates for the various key phases of works. Any payment under the contract shall be made only after the contractor’s price break-up is approved by the Engineer. The aggregate sum of the contractor’s price break down shall be equal to the lump sum contract price. 53.04 Application for Payments The Contractor shall submit application for the payments in the prescribed proforma of the purchaser. The foreign contractor shall submit to the Engineer separate applications for payment in different currencies whenever payment is to be made in more than one currency. Each such application shall state the amount claimed and shall set forth in details, in the order for the payment schedule particulars of the works including the works executed at site and of the equipment shipped/brought on to the site pursuant to the contract up to the date mentioned in the application and for the period covered since the last preceding certificate, if any. Every interim payment certificate shall certify the contract value of the works executed up to the date mentioned in the application of the payment certificate, provided that no sum shall be included in any interim payment certificate in respect of the works that, according to the decision of the Engineer, does not comply with the contract, or has been performed, at the date of certificate prematurely.
53.05 Terms of Payment Subject to any deduction which the Purchaser may be authorized to make under the contract, the Contractor shall, on the certificate of the Engineer be entitled to payments generally as follows: A)
Supply -
80% shall be paid for each consignment dispatched pro-rata against presentation of each invoices and evidence of shipment/dispatch.
-
10% shall be paid after completion of erection.
-
10% shall be paid after completion of satisfactory commissioning and performance guarantee tests.
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B)
Marine Freight and Insurance The ocean freight wherever payable shall be paid on production of invoices, evidence of shipment and other supporting documents for ocean freight and marine insurance components. In case of contracts inclusive of ocean freight and marine insurance total of the payments shall not exceed the total amount quoted by the Contractor in his bid.
C)
Inland Transportation and Inland Insurance Inland transportation (including port handling) shall be paid after the equipment has been received at site on production of invoices for such charges. Wherever this is included in the contract the aggregate of all such invoices shall not exceed the total amount indicated by the Contractor in his proposal.
D)
Erection Services -
80% shall be paid for the progress made during the month on monthly progress bills against certification by the Engineer.
-
10% shall be paid on completion of erection and Tests on Completion.
-
10% shall be paid on completion of the successful commissioning and guarantee tests.
54.00 MISCELLANEOUS 54.01 Entire Agreement These General Conditions together with the specification, tender drawing and guaranteed technical particulars, tender data with subsequent agreed modification thereof shall constitute the entire Agreement between the parties in respect of the subject matter hereof. No variation or modification of the contract or waiver of any of the terms and conditions thereof shall be deemed valid unless in writing and signed by the parties hereto. 54.02 General Conditions of Contract, the tender specifications and other contract / tender documents are to be taken as mutually explanatory to one another. However, in case of conflict between these documents, the technical specification, special conditions of the contract and general conditions of the contract shall have precedence in that order. 54.03 Endorsement of Terms The failure of either party to endorse at any time any of the provisions of the contract or any rights in respect thereto or to exercise an option herein provided shall in no way be construed to be a
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waiver of such provisions, rights or option or in way to effect the validity of the Contractor. The exercise by either party of any of his rights here in shall not preclude or prejudice either party from exercising the same or any other right it may have hereunder. 54.04 Contract Labor Regulation & Abolition The Contractor shall be responsible for all statutory obligations under Contract Labor (Regulation & Abolition) Act 1970. E.S.I. and Provident Fund Acts, as applicable, for their labor and staff engaged in executing this work. The Contractor will also keep the Purchaser indemnified against all claims and disputes arising out of death or injury to their workmen and staff. It will be necessary for the contractor to ensure that proper safety measures are followed by their workmen to avoid accident/damage/loss to life and property. Approved safety belts must be used by their workmen when working at any height. Charges for above are deemed included in the quoted rates and accepted amount. 54.05 Recover of Damages Nothing contained in the conditions or in any other part of this Contract shall be construed as preventing the Purchaser from the Contractor any damages to which the purchaser may be entitled in law as a consequence of any breach by the Contractor of any of the terms of this Contract.
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ANNEXURE - IV ADDENDUM TO TENDER DOCUMENT (COMMERCIAL) 1.0
SCOPE
1.1
The subject enquiry is being issued on turnkey basis with entire responsibility of design, engineering up to Commissioning and handing over of plant / equipment / system to the Owner. Owner intends to enter into two separate contracts (if placed) as follows to rationalize tax liability as per legal provision of country and also for operational convenience.
(a)
Basic design, engineering, supply of equipments and materials including all necessary accessories, Spares at Site
(b)
Unloading, storage, handling of equipments at site, complete Construction, Erection, Testing and Commissioning services, Supervision and Training Services
1.2
The Contract-cum-Performance Bank Guarantee for 10% of Total Order Value for both the contracts shall be furnished by the vendor to the Owner.
2.0
PAYMENT TERMS
2.1
Following Payment Terms will be applicable:
(i)
For Supply (including Design & Engineering):
(ii)
(i)
80% payment on prorate basis against presentation of dispatch documents.
(ii)
10% payment shall be made after completion of erection.
(iii)
Balance 10% payment shall be made after final handing over of equipments to the Owner at site.
Inland Transportation Charges for inland transportation shall be paid after the equipment is received at Site against invoices.
(iii)
2.2
Site Work (i)
90% against monthly progressive billing duly certified by Site In- charge.
(ii)
10% within 30 days of final handing over of the equipment to Owner at site.
Invoices should be submitted along with certificate stating “It is certified that Cenvatable/ VAT Invoices have been issued in the name of consignee, for full amount of Excise Duty/ Sales Tax/ Service Tax charged in the Invoice, as per rules in force. Vendor agrees to reimburse Excise Duty/ Page 1 of 11
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Sales Tax/ Service Tax, if documents are not found to be in order for claiming Cenvat/ VAT benefits.” 2.3
NOTE:
(i)
Final Handing Over: Final Handing Over shall mean Commissioning including acceptance of PG Tests. However, in case PG Test could not be conducted within 6 months from commissioning, for reasons not attributable to vendor, last 10% payment will be released against a Bank Guarantee of equal amount valid for 12 months initially and extendable thereafter.
(ii)
Payment for indigenous supply shall be through Bank against dispatch documents. Payment through bank shall be as per normal banking procedure. Direct Payment can be made through e-payment mode through SBI as well as NEFT/RTGS mode through designated enabled branches. In case of Direct Payment, duly filled Bank Mandate form in duplicate should be furnished with due authentication from bidder’s Banker
3.0
TAXES & DUTIES
3.1
All taxes and duties including Excise Duty and concessional CST/ VAT but excluding Sales Tax on Works Contract will be paid against Documentary Evidence at actuals limited to amount quoted in price bids. However, statutory variations (on finished products) will be allowed against documentary evidence. Vendor shall provide break up along with billing schedule subject to ceiling limit quoted in price bid.
3.2
Service Tax and E-cess applicable should be clearly indicated with ceiling limit to be paid against documentary evidence and invoice raised in line with Service Tax Rule to enable NALCO to avail Cenvat.
3.3
Vendors are required to quote prices inclusive of Works Contract Tax and no variation is payable on this account. In case vendor insists on WCT variation, rate of WCT and amount should be mentioned in the bid, without which statutory variation will not be admissible.
3.4
It is to be noted that the Contractor shall be required to submit the documentary evidence(s) for Excise Duty paid by them to concerned authorities for Owner to claim CENVAT benefit.
3.5
Necessary Cenvatable documents such as Transporter’s copy of Challan / Bill of Entry Triplicate Copy for availing Cenvat benefit to be given in NALCO’s name indicating consignee as NALCO for availing Excise Duty, Copy of Registration with Central Excise Authority and any other document required by the Owner shall be furnished by Contractor to enable Owner to claim CENVAT.
3.6
The classification of goods as per Central Excise Customs Tariffs should be correctly done to ensure that CENVAT benefits is not lost by the Owner on account of any error on the part of the Contractor. The Owner shall be at liberty to withhold the payment of cenvatable duties (viz. Central Page 2 of 11
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Excise Duties, Countervailing Duties of Customs etc.) If the requirements as specified in the clause are not fulfilled by the Contractor. The price of materials shall stand reduced accordingly. 3.7
The Contractor shall furnish the details of Excise Duty and CD/CVD component included his price for the purpose of cenvat benefit. The amount of ED and CVD indicated as part of Quoted Price is for information only. Contractor is required to pay all taxes & duties nevertheless and must furnish Cenvatable documents for the amount of ED and CVD paid by him, subject to minimum of the amount of ED and CVD indicated by him in his bid.
3.8
Entry Tax shall be paid by NALCO for consignments coming from outside Orissa. For supplies to be made from Orissa, Entry Tax shall be paid by Seller and should be mentioned in the Invoices for reimbursement by NALCO.
4.0
INSURANCE
4.1
The Owner will arrange for insurance of equipment and material under the scope of the Contract as detailed in Tender Documents - Commercial.
4.2
The Contractor shall deal directly with the Insurance Company. The Contractor will be required to lodge all the claims of his part of the contract directly and arrange settlement as expeditiously as possible by complying with the required formalities and proper follow ups.
4.3
The contractor shall bear the entire cost of corresponding with the Insurer and arrange all documents/informations facilitating inspection/discussions by the officials/surveyors deputed by the Insurer. The Contractor shall make all efforts to get settlement of claim at the earliest and no time extension for completion of work will be given for delay on this account.
4.4
In respect of equipment damaged in transit or during erection & commissioning, the contractor shall arrange for replacement/ repair expeditiously. The replacement cost payable by the owner shall be limited to the invoice cost of damaged equipment. The cost payable for repair shall be mutually settled.
4.5
Contractor shall be liable solely to adhere to the requirements of the insurer for settlement of claims without prejudice to the rights of Contractor / NALCO / Insurer. Following steps are listed, however not exhaustively, for the information of contractor. (a) (b) (c) (d) (e)
Timely information for conducting survey. Protecting the rights of insurer while issuing acknowledgments. Lodging of monitory claims in time and furnishing of requisite documents to surveyors / insurers. Taking necessary precautions so that the loss/damage is not aggravated further. Damaged goods to be protected fully.
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4.6
Employees State Insurance Act
(i)
The Contractor agrees to and does hereby accept full and exclusive liability for the compliance with all obligations imposed by the Employee State Insurance Act 1948 and the Contractor further agrees to defend, indemnify and hold Owner harmless for any liability or penalty which may be imposed by the Central, State or Local authority by reasons of any asserted violation by Contractor or his Sub-contractor of the Employees’ State Insurance Act, 1948 and also from all claims, suits or proceeding that may be brought against the Owner arising under, growing out of or by reasons of the work provided for by this Contractor, whether brought by employees of the contractor, by third parties or by Central or State Government authority or any political sub-division thereof.
(ii)
The Contractor agrees to fill in with the Employee’s State Insurance Corporation, the Declaration forms, and all forms which may be required in respect of the Contractor’s or his Sub-contractor’s employees, who are employed in the WORK provided for or those covered by ESI from time to time under the Agreement. The Contractor shall deduct and secure the agreement of his subcontractor to deduct the employee’s contribution as per the first schedule of the Employee’s State Insurance Act from wages and affix the Employees Contribution Card at wages payment intervals. The contractor shall remit and secure the agreement of his sub-contractor to remit the State Bank of India, Employee’s State Insurance Corporation account the Employees contribution as required by the Act. The Contractor agrees to maintain all Cards and Records as required under the Act in respect of employees and payments and the contractor shall secure the agreement of his subcontractor to maintain such records. Any expenses incurred for the contributions; making contributions or maintaining records shall be to the Contractor’s or his Sub-contractor’s account.
(iii)
Owner shall retain such sum as may be necessary from the total value of contract until the Contractor shall furnish satisfactory proof that all contributions as required by the Employees State Insurance Act, 1948 have been paid. This will be pending on the Contractor when the ESI Act is extended to the place of work.
4.7
Workmen’s Compensation & Employer’s Liability Insurance Insurance shall be effected by Contractor for all their employees engaged in the performance of this Contract. If any of the work is sublet, the Contractor shall require his sub-contractor to provide workman’s Compensation and employer’s liability insurance for the later’s employees if such employees are not covered under the Contractor’s insurance.
4.8
Comprehensive Automobile Insurance This insurance shall be in such a form to protect the Contractor against all claims for injuries, disability, disease and death to members of public including the Owner’s men and damage to the property of others arising from the use of motor vehicles, during on or off the Site Operations, irrespective of the ownership of such vehicles.
4.9
Comprehensive General Liability Insurance This insurance shall protect the Contractor against all claims arising from inuries, disabilities, disease or death of members of public or damage to property of others, due to any act or omission Page 4 of 11
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on the part of the Contractor, his agents, his employees, his representative and Sub-Contractors or from riots, strikes and civil commotion. This insurance shall cover all the liabilities of the contractor arising out of the relevant clauses of enquiry documents. The hazards to be covered will pertain to all the works which and areas where, the Contrctor, his Sub-Contractors, his agents and his employees have to perform work pursuant to the contract. The above are only illustrative list of insurance covers normally required and it will be the responsibility of the contractor to maintain all necessary insurance coverage to the extent both in time and amount to take care of all his liabilities either direct or indirect, in pursuance of the contract. 4.10
Any other Insurance required under Law or Regulations or by Owner Contractor shall also carry and maintain any and all other Insurance(s) which he may be required under any law or regulation from time to time without any extra cost to Owner. He shall also carry and maintain any other insurance which may be required by the Owner.
4.11
Accident or Injury to Workmen Owner shall not be liable for or in respect of any damages or compensation payable at law in respect or in consequence of any accident or injury to any workman or other person in the employment of the Contractor or his Sub-Contractor and the Contractor shall indemnify and keep indemnified the Owner against all such damages and compensation and against all claims, demands, proceedings, costs, charges and expenses, whatsoever in respect or in relation thereto.
5.0
CONSTRUCTION, ERECTION OF PLANT AND MATERIAL
5.1
Contractor’s Material brought on the Site The Contractor shall bring to Site all equipments, components, parts, materials, including construction equipment, tools and tackles for the purpose of the Works under intimation to the Owner. All such goods shall, from the time of their being brought vest in the Owner, but may be used for the purpose of the Works only and shall not on any account be removed or taken away by the Contractor without the written permission of the Owner. The Contractor shall nevertheless be solely liable and responsible for any loss or destruction thereof and damage thereto.
5.2
Work & Services to be provided by the Owner Works and services which shall be provided by the Owner for carrying out complete work at Site shall be as defined in the technical part of the Enquiry Documents and its clarification up to award of Contract. (a)
Water supply for construction purpose may be provided by the Owner at one mutually agreed point at Site. Drinking water will also be made available at one central point at Site. The Contractor shall make his own arrangement for any further distribution. Such distribution pipe network shall have the prior approval of the Engineer at Site so as not to Page 5 of 11
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interfere with the layout and progress of other construction works. Supply of water shall be charged from Contractor at the rates prevailing at Site. Contractor shall ensure that there is no wastage of water. On completion of the work, the Contractor shall remove all such work and shall reinstate and make good any work disturbed to the satisfaction of the Engineer. (b) 5.3
Cranes, if available, will be provided by Owner on payment of rent to the Owner.
Work and Services to be provided by the Contractor The following work and services shall also be provided under the contract :
5.4
(i)
Material transportation to erection site at Contractor’s risk and cost.
(ii)
All construction activities to complete the plant as per the specifications agreed by the Owner. The activities shall be included but not limited to building structures, rooms, foundations for equipments and accessories and stack etc.
(iii)
Labor license for contractor and sub-contractor’s labor if required / applicable as per State Govt.
Owner’s Lien on Equipments The Owner shall have lien on all equipments including those of the Contractor brought to the Site for the purpose of construction, erection, testing and commissioning of the plant. The Owner shall continue to hold the lien on all such equipments throughout the period of Contract. No material brought to the Site shall be removed from the Site by the Contractor and / or his Sub-contractors without the prior written approval of the Owner.
5.5
Protection of Work The contractor shall have total responsibility for protecting his Works till it is finally taken over by the Owner. No claim will be entertained by the Owner or the Consultant for any damage or loss to the Contractor’s Works and the Contractor shall be responsible for the complete restoration of the damaged works to its original condition to comply with the specifications and drawings. Should any such damage to the Contractor’s Works occur because of other party not under his supervision or control, the Contractor shall make his claim directly with the party concerned. If disagreement or conflict or dispute develops between the Contractor and the party or parties concerned regarding the responsibility for damage to the Contractor’s Works the same shall be resolved as per the provisions of the clause entitled ‘Co-operation with other Contractors’. The Contractor shall not cause any delay in the repair of such damaged works because of any delay in the resolution of such disputes. The Contractor shall proceed to repair the work immediately and no cause thereof will be assigned pending resolution of such dispute.
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5.6
Security The Contractor shall have total responsibility for all equipments and materials in his custody stored, loose, semi-assembled and / or erected by him at Site. The Contractor shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. All materials of the Contractor shall enter and leave the Project Site only with the written permission of the Owner in the prescribed manner. Contractor’s employees shall wear identification badges while on the work at Site.
5.7
Contractor’s Area Limits The Owner will mark-out the boundary limits of access road, parking spaces, storage and construction areas for the Contractor and the Contractor shall not trespass the areas not so marked out for him. The Contractor shall be responsible to ensure that none of his personnel move out of the areas marked out, for his operation. In case of such a need for the Contractor’s personnel to work, out of the areas marked out for him, the same shall be done only with the written permission of the Owner.
5.8
Contractor’s Co-operation with the Owner In cases where the performance of the Site Work by the Contractor affects the operation of the system facilities of the Owner such Site Work of the Contractor shall be scheduled to be performed only in the manner stipulated by the Owner and the same shall be acceptable at all times to the Contractor. The Owner may impose such restriction on the facilities provided to the Contractor such as electricity, water, etc. as he may think fit in the interest of the Owner and the Contractor shall strictly adhere to such restrictions and co-operate with the Owner. It will be responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and operation of the equipment systems which are erected by him. The Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants required for the equipment supplied and erected by him, so as to make such equipments ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in these documents and specifications.
5.9
Protection of Property and Contractor’s Liability
5.9.1
The Contractor shall be responsible for any damage resulting from his operations. He shall also be responsible for protection of all persons including members of public and employees of the Owner and the employees of other Contractors and Sub-Contractors and all public and private property including structurs, building, other plants and equipments and utilities either above or below the ground.
5.9.2
The Contractor will ensure provisions of necessary safety equipment such as barriers, sign-boards, warning lights and lamps, etc. to provide adequate protection to persons and property. The Contractor shall be responsible to give reasonable notice to the Owner and the Owner of public or private property and utilities when such property and utilities are likely to get damaged or injured Page 7 of 11
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during the performance of his works and shall make all necessary arrangements with Owners, related to removal and/or replacement of such property and utilities. 5.10
Painting All exposed metal parts of the equipment including piping, structures railing, etc. wherever applicable, after installation unless otherwise surface protected, shall be first painted with at least one coat of suitable primer which matches the shop primer paint used, after thoroughly cleaning all such parts of all dirt, rust, scales, greases, oil and other foreign materials by wire brushing, scraping or sand blasting, and the same being inspected and approved by the Engineer for painting. Afterwards, the above parts shall be finished with two coats of a alloyed resin machinery enamel paints. The quality of the finish paint shall be as per the standards of ISI or equivalent and to be of the colour as approved by the Owner.
5.11
Unfavorable Working Conditions The Contractor shall confine all his field operations to those works which can be performed without subjecting the equipment and materials to adverse effects, during inclement weather conditions, like monsoon, storms, etc. and during other unfavourable construction conditions. No field activities shall be performed by the Contractor under conditions which might adversely affect the quality and efficiency thereof unless special precautions or measures are taken by the Contractor in a proper and satisfactory manner in the performance of such works and with the concurrence of the Consultant/Owner. Such unfavorable construction conditions will in no way relieve the contractor of his responsibility to perform the works as per the schedule.
5.12
Protection of monuments and reference points The Contractor shall ensure that any finds such as relic, antiquity, coins, fossile, etc. which he may come across during the course of performance of his works either during excavation of elsewhere, are properly protected and handed over to the Owner. Similarly, the Contractor shall ensure that the bench marks, reference points, etc. which are marked out either with the help of Owner or by the Owner shall not be disturbed in any way during the performance of his works. If any work is to be performed which may disturb such reference, the same shall be done only after these are transferred to other suitable locations under the direction of the Owner.
6.0
CONSTRUCTION
6.1
Rules and Regulations Contractor shall observe all national and local laws, ordinaces, rules and regulations pertaining to the work, and shall be responsible for extra costs arising from violations of same.
6.2
Safety Contractor shall take all necessary measures to protect the work and workmen against accidents and occupational disease. They shall observe and comply with all Government safety regulations as specified by the Owner. Page 8 of 11
Tender Notice No. - …………..............
The Contractor shall be responsible for following the proper procedures in reporting accidents or incident. The Owner’s Safety Engineer located in Site will be immediately notified by faster means possible of any accident which involves the following: (a) (b) (c) (d) (e) (f)
Death from any cause whatsoever. A fractured skull, arm, thigh or spine, fore-arm or leg. A dislocated shoulder. The amputation of arm or hand, or of one or more fingers on the same hand, or of a leg or a foot. The loss of sight of an eye. Any other serious bodily injury, including internal bleeding or burns or asphyxia where such injury is likely to endanger life, cause permanent incapacity or temporary incapacity of 5 days or more.
6.3
In case of death, the Contractor shall be responsible for immediately notifying the nearest Indian Police so that they can make the proper investigation in accordance with the law.
7.0
FOREIGN LIABILITY CLAUSE It is expressly understood and agreed by and between (the Corporation0 and M/s National Aluminium Company Limited (The Indian PSU) that M/s National Aluminium Co. Ltd. (the Indian PSU) is entering into this agreement solely on its own behalf and not on behalf of any other person or entity. In particular, it is expressly understood and agreed that the Government of India is not a party to this agreement and has no liabilities, obligations or rights hereunder. It is expressly understood and agreed that M/s National Aluminium Co. Ltd. (the Indian PSU) is an independent legal entity with power and authority to enter into contracts solely in its own behalf under the applicable Law of Indian and General Principles of Contract Law. The (Company) expressly agrees, acknowledges and understands that M/s National Aluminium Co. Ltd. (the Indian PSU) is not an agent, representative or delegate of the Government of India. It is further understood and agreed that the Government of India is not and shall not be liable for any acts, omissions, commissions, breaches or other wrongs arising out of the Contract. Accordingly (corporation) hereby expressly waives, releases and foregoes any and all actions or claims including cross claims, impleader claims or counter claims against the Government of India arising out of this contract and covenents not to sue the Government of India as to any manner, claim, cause of action or thing whatsoever arising of or under this agreement.
8.0
CLAUSE 44.02: REGULATION OF LOCAL AUTHORITIES & STATUES (TENDER DOCUMENT COMMERCIAL - INDIGENOUS)
8.1
The following is to be read along with Clause 44.02:(a) The payment of minimum wages to Contract Labour shall be as per the rates notified by the central Government as per Minimum Wages Act,1948 and as adopted by the NALCO Management from time to time plus any additional element and statutory dues thereon. Page 9 of 11
Tender Notice No. - …………..............
(b) The Minimum wage as notified by the Chief Labour Commissioner (central) has a variable component as Special allowance which is linked to average AICPI for Industrial Workers, which keeps on changing every six months. The Contractor has to absorb all such variations due to increase in Minimum wage in their quoted price and no claim whatsoever on this account shall be entertained. (c) Where the Minimum wages notified by the concerned State Government are higher than the rates notified by the Central Government, the States Government rates should apply in concerned scheduled employment as long as the same remains higher than the Central Government rates. (d) The classification on workers in different categories will be as per the notification issued by the Central Government fixing the minimum wages for the above scheduled appointment. 8.2
The classification of workers in different categories will be as per the notification issued by the Central government fixing the minimum wages for the above scheduled appointment. Where the minimum wages notified by the concerned State Government are higher than the rates notified by Central Government, the State Government rates should apply in concerned scheduled employments.
9.0
GUARANTEE PERIOD Guarantee Period shall be 12 months from commissioning (including acceptance of Performance Guarantee Tests) or 24 months from completion of erection, whichever is earlier. All other provisions of the clause remain unaltered.
10.0
CONTRACT PERFORMANCE GUARANTEE Supplier will be required to submit Contract - cum - Performance Bank Guarantee (CPBG) for 10% of Total Order Value (Supply + Transportation + Supervision + Site Work) for the complete package within 30 days of placement of order with validity up to 3 months beyond Guarantee Period. All payments shall be released after receipt of CPBG.
11.0
CONSTRUCTION POWER Construction power rate indicated in Tender Documents Commercial is modified as “As applicable at Site” in place of Rs. 1/- per KWH.
12.0
PRICE REDUCTION SCHEDULE
(i)
Liquidated Damages (LD) wherever mentioned in NIT documents, is to be read as Price Reduction Schedule (PRS).
(ii)
The Contractor’s liability for delay shall not in any case exceed five percent of the total contract price. All other provisions of these clauses remain unaltered. Page 10 of 11
Tender Notice No. - …………..............
13.0
POWER TO VARY OR OMIT WORK
13.1
In partial modification to clause No. - 29 of GCC - Indigenous the last sentence of this clause is amended as follows: “In the absence of any such modification, the contractor shall bind to carry out the suggested variations. Any addition or deletion to price will be discussed between purchaser and contractor and settled.”
13.2
All other provisions of this clause remain unaltered. Note: The terms and conditions mentioned herein will prevail over the terms mentioned in tender document commercial (indigenous).
Page 11 of 11
ANNEXURE - V AGREED TERMS & CONDITIONS (INDIGENOUS) NALCO, SMELTER PLANT (FOR INDIGENOUS BIDDERS) IMPORTANT 1.
This questionnaire must be filled in against all Serial nos. & enclosed with the Un-priced offer. Non submission or submission of incomplete questionnaire may lead to rejection of the offer.
2.
All commercial terms except the deviations to Tender Documents - Commercial (Indigenous), Addendum to Tender Documents and other attachments of NIT must be given in this questionnaire itself and not elsewhere in the quotation. In case of contradiction, the terms given below shall prevail. The deviations to Tender Documents - Commercial (Indigenous), Addendum to Tender Documents and other attachments of NIT, if any must be listed in a separate Annexure.
Sl. No.
Descriptions
Vendor’s confirmation with details
(A)
TECHNICAL:
1. (i)
Acceptance of Technical specifications and scope of supply as per attached Annexure - I Technical Specification.
(ii)
In case of deviations, confirm that the same has been highlighted separately.
2.
Confirm that data sheets/ technical questionnaire duly filled in are attached, wherever required.
3.
Confirm Spare parts list, wherever required with item wise prices have been submitted for following categories of Spares. (a) (b) (c) (d)
4.
Mandatory Spares Commissioning Spares Recommended Spares for One Year normal operation and maintenance Special Tools & Tackles
It is noted that deviations to terms & conditions shall lead to loading of prices or rejection of offer.
Page 1 of 7
Sl. No.
Descriptions
Vendor’s confirmation with details
5.
Confirm that the quoted prices are based on FOR/ FOT Despatch point including packing & forwarding.
(i)
If quoted on Ex- works basis, indicate P&F charges in terms of percentage.
(ii)
Indicate despatching station.
6.
Confirm you have quoted prices strictly in the price schedule format enclosed with NIT documents.
7.
Please confirm that firm freight charges inclusive of applicable Service Tax and E-cess up to Site is quoted in price bid.
(a)
In case you have not quoted the freight charges separately in the Price Schedule, please quote the same in terms of % of the quoted price.
(b)
Confirm that freight charges for Recommended Spares for One Year normal O&M have been quoted separately and the freight for all other supplies are included in freight of Main Equipment.
8.
Confirm Transit insurance is excluded from the quoted prices. If inclusive, indicate rebate for excluding the same.
9.
Indicate rate of Central Sales Tax/Orissa VAT payable extra.
(i) (ii) (iii)
CST without concessional Form. CST with concessional Form. Orissa VAT
Page 2 of 7
Sl. No.
Descriptions
Vendor’s confirmation with details
10(a)
Statutory increase in Excise Duty & Education cess beyond contractual delivery date shall be to vendor’s account but any reduction up to actual date of despatch shall be to owner’s account.
(b)
Indicate present rate of Excise Duty & Education Cess applicable on the supplies (including Spares) and whether the same is included/ excluded from quoted prices.
(c)
If there is any increase in ED & E-cess at the time of supplies for any reasons, other than statutory, including turnover, confirm the same will be borne by the vendor.
(d)
If ED & E-ces is presently not applicable, confirm whether the same will be borne by the vendor in case it becomes leviable later.
(e)
In case (c) or (d) is not acceptable, advise maximum rate of ED & E-cess chargeable.
11.
Entry Tax on supplied items shall be paid by Nalco directly to Tax Authorities. However, any Entry Tax applicable for items and consumables etc used for Erection/ Commissioning shall be to Seller’s account.
12.
Confirm submission of following documents with offer: 1) Valid Excise Regn. Certificate. 2) Valid Sales Tax Regn. Certificate. 3) Valid Service Tax Regn. Certificate. 4) TIN (Tax Identification No.)
13.
Confirm in case of delay on a/c of vendor, any new or additional taxes and duties imposed after contractual delivery shall be to vendor’s account.
Page 3 of 7
Sl. No.
Descriptions
Vendor’s confirmation with details
14.
Confirm acceptance to delivery/ Completion period as mentioned in NIT documents.
15.
Confirm acceptance to Price Reduction Schedule clause specified in Tender Documents.
16.
Confirm acceptance of relevant terms of payment as per the NIT documents attached.
17.
Confirm that the quoted prices are firm and fixed till complete execution.
18.
Confirm that Contract cum Performance/ Performance Bank Guarantee wherever required will be furnished for value and terms & conditions as per document attached with NIT.
19.
Confirm that Bank Guarantee for equivalent amount of Free Issue Materials, wherever applicable, shall be furnished.
20.
Confirm acceptance of Guarantee/ Warranty as per documents attached with NIT.
21.
Confirm that quoted prices are inclusive of all Testing charges as required in the NIT.
22(i)
All other Commercial terms & conditions shall be as per Tender Documents - Commercial (Indigenous), Addendum to Tender Documents Commercial and other documents attached with the NIT. Confirm.
(ii)
In case of deviations, confirm clause wise comments have been specified in a separate Annexure.
(iii)
All the terms & conditions have been indicated in this format including Annexure and have not been repeated elsewhere. It is noted that terms & conditions indicated elsewhere shall be ignored.
Page 4 of 7
Sl. No.
Descriptions
Vendor’s confirmation with details
23.
Confirm that all taxes, duties and levies of any kind payable by Seller up to the stage of handing over of the system to Owner shall be borne by you.
25.
Import permit/ Licence, if required shall be the responsibility of the Seller and any expenditure towards the same shall be borne by you. Please confirm.
26.
In case of any Imported supply to be quoted in INR by Indian Associate, confirm that all variations in Customs Duty and Foreign Exchange till complete execution of the contract shall be to Seller’s account.
27.
The vendor is required to state whether any of the Directors of vendor is a relative of any of the Directors of Owner or the vendor is a firm in which any Director of Owner or his relative is a partner or the vendor is a Private Company in which any of the Directors of Owner is a member or Director.
28.
Confirm that the offer shall be valid up to 4 months from the bid due date/ extended bid due date.
29.
Please furnish Annual Report containing Balance Sheet and Profit and Loss Account for the last three years.
30.
Confirm that net worth of your company during the last financial year is positive.
31.
As soon as shipment/ dispatch is made, the Seller shall intimate NALCO’s Underwriters the dispatch details t the address which shall be furnished later.
32.
The Vendor is required to state whether M/s AP/ ALCAN has any shareholding/ management control in your Company. Page 5 of 7
Sl. No.
Descriptions
Vendor’s confirmation with details
33.
Please note that you have not been banned or de-listed by any Government or Quasi Government agencies or PSU.
34.
Confirm that in case of conflicting version of various terms & conditions at different places, Owner can choose any version.
35.
Please furnish name and address of the official to whom correspondence should be sent including telephone number/ fax number and e-mail id. If email id is not available, an undertaking is to be given that e-mail id is to be registered within 2 weeks of bid submission Place:
Signature:
Date:
Name :
Page 6 of 7
Designation
:
Seal
:
DEVIATIONS TO NIT DOCUMENTS
SL. NO.
REFERENCE OF NIT DOCUMENT DOCUMENT
SUBJECT
DEVIATIONS
CLAUSE NO.
NOTE: This shall be submitted along with the Un - priced Offer. Deviation mentioned anywhere else in the offer shall not be considered. Signature: Date:
Name :
Page 7 of 7
Designation
:
Seal
:
Tender Notice No. - …………………...............
Annexure - VI PRICE SCHEDULE FORMAT ITEM:
WAGON TIPPLER AND CONVEYOR SYSTEM
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT
1.0 1.1
1.2 1.3 2.0 2.1 2.2 2.3
INDIGENOUS SUPPLY (IN INDIAN Rs.) (M/s …………..)
SUPPLY OF MAIN EQUIPMENT Design, Engineering, Manufacturing, Procurement, Inspection, Assembly, Painting, Testing at Supplier’s works, Packing & Forwarding and Supply of Wagon Tippler & Accessories including Commissioning & Start-up Spares, Tools & Tackles , first fill of oil & lubricants/ oil and consumables as per Annexure - I - Technical Specification of NIT on FOT Dispatch point basis including packing & forwarding (break - up of prices to be submitted as per Annexure - A attached herewith) Supply of Mandatory Spares, as per NIT (itemized prices to be furnished along with the price bid) on FOT dispatch point basis including packing & forwarding Others if any to complete the Scope (Pl specify) SUB TOTAL (1.0) FREIGHT, INSURANCE, TAXES & DUTIES ON ITEMS UNDER SUB HEADING 1.0 Total & maximum Excise Duty & E-cess on ED (Amount payable against Cenvatable Invoices ) Total & maximum Central Sales Tax (Considering CST Declaration form to be furnished by NALCO, wherever applicable/ admissible) Total & Maximum Orissa VAT applicable for items to be supplied from within the state of Odisha Page 1 of 7
ERECTION/ TESTING/ COMMISSIONING SERVICES AT SITE , SUPERVISION & TRAINING SERVICES (IN INDIAN Rs.) (M/s ……………….)
Tender Notice No. - …………………...............
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT 2.4 2.5 2.6
3.0 3.1
3.2 3.3
3.4 3.5 3.6 3.7
INDIGENOUS SUPPLY (IN INDIAN Rs.) (M/s …………..)
All other taxes & duties currently applicable (Please specify the nature of Tax/ Duty & its rate) Inland freight charges up to Site including Service Tax & Ecess on same Transit Insurance up to Site (Optional) inclusive of all taxes SUB TOTAL (2.0) SUPPLY OF ONE YEARS O&M SPARES FOR TROUBLE FREE OPERATION - OPTIONAL Supply of vendor recommended Spares for One year O&M on FOT dispatch point basis (itemized prices to be furnished along with the price bid, list of spares to be furnished along with un - priced bid) Total & maximum Excise Duty & E-cess on ED (Amount payable against Cenvatable Invoices ) Total & maximum Central Sales Tax (Considering CST Declaration form to be furnished by NALCO, wherever applicable/ admissible) Total & Maximum Orissa VAT applicable for items to be supplied from within Orissa All other taxes & duties currently applicable (Please specify the nature of Tax/ Duty & its rate) Inland freight charges up to Site including applicable Service Tax & E-cess Transit Insurance up to Site (Optional) inclusive of all taxes SUB TOTAL (3.0 )
Page 2 of 7
ERECTION/ TESTING/ COMMISSIONING SERVICES AT SITE , SUPERVISION & TRAINING SERVICES (IN INDIAN Rs.) (M/s ……………….)
Tender Notice No. - …………………...............
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT 4.0 4.1
UNLOADING, STORAGE, HANDLING & TRANSPORTATION OF EQUIPMENT/ MATERIALS AT SITE For Main Equipment under Sl. No. - 1.0 above
4.2
For One Year O&M Spares under Sl. No. - 3.0 above
4.3
Total & Maximum Service Tax for 4.1 Total & Maximum E-cess for 4.1 Total & Maximum Service Tax for 4.2 Total & Maximum E-cess for 4.2
4.4 4.5 4.6
INDIGENOUS SUPPLY (IN INDIAN Rs.) (M/s …………..)
SUB TOTAL (4.0) 5.0
CONSTRUCTION, ERECTION, TESTING, COMMISSIONING AND PERFORMANCE GUARANTEE TESTS
5.1
Civil & Structural Work as per NIT
5.2
Erection - Mechanical
5.3
Electrical and Instrumentation works
5.4
Testing, Commissioning and Performance Guarantee Tests.
5.5
All statutory/contingency insurance coverage e.g. third party liability, ESI, workmen compensation etc.
5.6
Total for Construction, Erection, Testing, Commissioning and Performance Guarantee Tests
5.7
Insurance coverage for storage erection & commissioning etc. (Optional)
5.8
Orissa VAT on Works Contract (Works Contract Tax) as currently applicable Page 3 of 7
ERECTION/ TESTING/ COMMISSIONING SERVICES AT SITE , SUPERVISION & TRAINING SERVICES (IN INDIAN Rs.) (M/s ……………….)
Tender Notice No. - …………………...............
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT 5.9
Any other Indian taxes/ duties currently applicable
5.10
Total & maximum Service Tax.
5.11
Total & maximum E- cess on Service Tax.
5.12
Others, if any.
INDIGENOUS SUPPLY (IN INDIAN Rs.) (M/s …………..)
ERECTION/ TESTING/ COMMISSIONING SERVICES AT SITE , SUPERVISION & TRAINING SERVICES (IN INDIAN Rs.) (M/s ……………….)
SUB TOTAL (5.0) GRAND TOTAL ( SUM OF 1.0 T0 5.0 ) NOTES: 1.
The Price Schedule shall be made available in Un-priced offer also with prices blanked out and written “Quoted/ Not Quoted/ Not Applicable”, as the case may be.
2.
In the Price Schedule no column should be left blank.
3.
The quoted prices shall include charges towards testing & all documentation required as per NIT.
4.
Any correction in the quotation shall be initialed by the bidder, otherwise the offer shall be rejected.
5.
Bidders are required to quote prices inclusive of Works Contract Tax or Orissa VAT on Works Contract and any variation is not payable on this account. Liability of Works Contract Tax on Erection/ Testing/ Commissioning for Service Contract i.e. Contract C shall be solely of Contractor. NALCO would deduct WCT in line with NIT provisions while releasing payment to Contractor and deposit the same with Sales Tax Authority and issue TDS to Contractor from time to time. Contractor will settle WCT directly with the Sales Tax Authority without any liability on the part of NALCO. Bidders are required to include the WCT into their price, as applicable, and it would be deemed that the same has been taken into consideration by them, irrespective of whether such WCT amount has been indicated separately or not. Accordingly, there would be no loading (i.e. there will be no like to like comparison) even if any agency does not indicate such amount or such percentage in their price bid. However, WCT mentioned in the price schedule by a bidder shall be considered for evaluation of his price.
6.
Applicable Service Tax & E-cess on Service Tax will be paid at actuals subject to documentary evidence limited to the maximum amount quoted. Page 4 of 7
Tender Notice No. - …………………...............
7.
Entry Tax on supplies against supply of items shall be paid by NALCO directly to Tax authorities.
8.
The sum of quoted prices for relevant divisible package (s) shall be treated as the Contract price(s) for concerned package(s) on lump sum basis. The contract vis-à- vis payment operations shall be done, however, as per approved Billing schedules only.
9.
The Contract (s) prices, will remain firm & unchanged until complete execution excepting for statutory variations, if any on the rates of taxes & duties included in the Contract price ( as per break ups specified in the Billing schedule) and also excepting for imposition of any fresh statutory levy/ tax.
10.
In case of award of work, the Contractor has to submit a Billing Schedule for approval of NALCO/RITES. The payment of bills involving Excise duty shall be made at actuals against submission of Cenvatable ED invoices but limited to the quoted ED & E-cess on ED.
11.
Optional prices shall not be considered for evaluation. However, the optional prices shall be valid during execution of Contract and could be exercised by NALCO, in case NALCO decides the same.
12.
Supply of spares parts for One Year normal operation and maintenance as per Sl. No. - 3.0 of Price Schedule shall not be considered for evaluation. However, the prices shall be valid and separate order shall be placed for such spares which are decided by NALCO. Sl. No. - 4.2, 4.5 & 4.6 shall not be considered for evaluation. Bidder shall submit Price break - up along with quantity and unit price for the Spares for 1 year normal operation and maintenance in priced and un - priced format.
13. 14.
Bidder shall submit Price break - up along with quantity and unit price for the following in Priced & Un-priced format:
(a) (b) (c) (d)
Mandatory Spares Commissioning & Start-up Spares Tools & Tackles Spares for One Year O&M
Bidder’s Signature: Bidder’s Stamp: Date: Page 5 of 7
Tender Notice No. - …………………...............
ANNEXURE-A TO PRICE SCHEDULE FORMAT Description of Item 01. Design, Manufacture and Supply of Wagon Tippler System 25 tips / hour design capacity (20 tips per hour guaranteed output) complete with tippler platform with rails, cradle, top & side clamps, etc. including all electricals and instrumentation and required other connected accessories. 02. Design, Manufacture and Supply of Side Arm charger (25 wagons per hour) 20 wagons per hour guaranteed capacity complete with all rails and travel mechanism.
Unit of measurement Lump sum
Quantity 1
Lump sum
1
03. Design, Manufacture and Supply of Apron feeder (1200 TPH) complete with dribble conveyor, feeder pans, suitable for underground hopper of tippler complete with drives, base plates and accessories required for fixing in foundation and other connected accessories complete.
Lump sum
1
04. Design, Manufacture and Supply of Receiving belt conveyor system 1200 TPH guaranteed capacity, 1200 mm belt width suitable for transport of coal received from apron feeder to existing conveyors BC-103 & BC-115 in plant including pent house, junction tower complete with stringers, supports, Idlers, Belt, Pulleys, chutes and safety devices, foundations, supports overhead gallery and trestle etc. with all electricals and plc control accessories. 05. Design, Manufacture and Supply of Dust control system at Wagon Tippler House, transfer points of conveyor complete with all civil, mechanical and electricals works.
Lump sum
1
Lump sum
1
06. Design, Manufacture and Supply of E.O.T. Crane 25T / 5T capacity suitable to handle the erection and Maintenance requirements of wagon tippler, apron feeder, etc.
Lump sum
1
07. Design and supply of Mono rail hoists of appropriate capacity for equipments, drivers, pulley and Gear reducers, apron feeder at various location within the terminal points complete with all accessories.
Lump sum
1
08. Design and supply of Fire hydrant system covering Wagon Tippler House, Conveyor Galleries, Transfer House etc. extending from existing fire water grid in the vicinity within Plant area with all necessary accessories complete.
Lump sum
1
Page 6 of 7
Unit Price
Tender Notice No. - …………………...............
Description of Item 09. Design and supply of Service water connections at Transfer Towers, tippler house, at each floor level complete system extending from the existing header near the new track hopper with all accessories for complete system.
Unit of measurement Lump sum
Quantity 1
10. Design and supply of Illumination and lighting system for Wagon Tippler House, Transfer Towers, Conveyor Galleries and control rooms etc. with all accessories.
Lump sum
1
11. Design and supply of ACSR cables, rail poles, insulators, hardware fittings, 33KV/6.6KV transformer complete, breakers, isolators, CT, PT, LA, switch gear, etc. for HT system as per scope of work.
Lump sum
1
12. Design and supply of cables, 6.6KV/415V transformer complete, switch gear, panels, etc. LT system as per scope of work.
Lump sum
1
13. Supply of all control cables, Panels, PLCs etc. complete for the system.
Lump sum
1
LUMP SUM PRICE TOTAL
Page 7 of 7
Unit Price
ANNEXURE - VII PROFORMA OF CONTRACT CUM PERFORMANCE GUARANTEE BY SELLER/CONTRACTOR (To be executed on non-Judicial stamped paper of appropriate value) B.G. No. - ………………
Date: …………………
WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its Office at Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter called "the Company/Owner") which expression shall unless repugnant to the subject or context includes its legal representatives, successors and assigns), has entered into a contract with M/s. ………………../ has placed a purchase order on M/s. ………………… (hereinafter referred to as “Contractor(s)/Seller(s)”) which expression shall unless repugnant to the subject or context includes their legal representatives, successors and assigns) for .............................. on the terms and conditions as set out inter alia, in the company Contract No/P.O. No.............................. dt............. and various documents forming part thereof herein after referred to as the “said contract” which expression include all amendments, modification and/or variation thereto and where as the Contractor/Seller has agreed for due execution of the entire contract and guarantees its performance including any parts executed through any others agencies/sub-contractors. AND WHEREAS one of the conditions of the “said contract” is that “contractor/seller shall furnish to the owner a Bank Guarantee from a bank for ......% (............. percent) of the total value of the “said contract” against due and faithful performance of the “said contract” including defects liability obligations and the performance guarantee obligations of the contractor/seller for execution/supplies made under the “said contract”. 2.
We ……………………….. Bank having its branch office at …………………. do hereby agree and undertake to pay the amount due and payable under this guarantee without any demur merely on a demand from the Company stating that in the opinion of the company which is final & binding, the amount claimed is due by reason of default made by the Contractor(s)/ Seller(s) in performing any of the terms and conditions of the said Contract including defects liability obligations, in fulfilling the performance Guarantee obligation or loss or damage caused to or would be caused to or suffered by the Company by reason of any breach by the said Contractor(s)/Seller(s) of any of the terms and conditions of the contract. Any such demand made on the Bank by the owner shall be conclusive as regards the amount due and payable by the Bank under this guarantee. However our liability under this guarantee shall be restricted to Rs.................. (Rupees........................... only)
3.
We undertake to pay to the Company any money so demanded not withstanding any dispute or disputes raised by the Contractor(s)/Supplier(s) in any suit or proceeding pending before any office, court or Tribunal relating thereto, our liability under this present being absolute and unequivocal. The payment so made by us under this bond shall be a valid discharge of our liability for payment there under. Our liability to pay is not dependent or conditional on the owner proceeding against the contractor(s)/seller(s).
4.
The guarantee herein contained shall not be determined or affected or suspended by the liquidation or winding up, dissolution or change of constitution or insolvency of the said Contractor(s)/ Seller(s) but shall in all respects and for all purposes be binding and operative until payment of all money due or liabilities under the said Contract(s)/Order(s) are fulfilled. Page 1 of 2
5.
We ……………………… Bank further agree that the guarantee herein contained shall remain in full force and effect during the period that would be taken for the performance of the said Contract(s)/Order(s) and that it shall continue to be enforceable till all the dues of the Company under or by virtue of the said Contract(s)/Order(s) have been fully paid and its claims satisfied or discharged or till a duly authorised officer of the Company certifies that the terms and conditions of the said Contract(s)/Order(s) have been fully and properly carried out by the said Contractor(s) and accordingly discharge this guarantee.
6.
We ................................. Bank further agree with the Company that the Company shall have the fullest liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the terms and conditions of the said Contractor(s)/ Order(s) or to extend time of performance by the said Contractor(s)/Seller(s) from time to time or to postpone for any time or from time to time any of the powers exercisable by the Company against the said Contractor(s)/Seller(s) and to forbear or enforce any of the terms and conditions relating to the said Contractor(s)/Seller(s) and we shall not be relieved from our liability by reason of any such variation or extension being granted to the said Contractor(s)/Seller(s) or for any forbearance, act or omission on the part of the Company or any indulgence by the Company to the said Contractor(s)/Seller(s) or by any such matter or thing whatsoever which under the law relating to sureties would but for this provision have effect of so relieving us.
7.
Notwithstanding anything contained herein before, our liability shall not exceed Rs………………….. (Rupees ………………….. only) and shall remain in force till …………….. unless a demand or claim under this guarantee is made on us within three months from the date of expiry we shall be discharged from all the liabilities under this guarantee.
8.
We ………………… Bank, lastly undertake not to revoke this guarantee during its currency except with the previous consent of the Company in writing. We further undertake to keep this Guarantee renewed from time to time at the request of Contractor(s)/Seller(s). Date: Corporate Seal of the Bank
......................Bank By its constitutional Attorney Signature of duly Authorised person on behalf of the Bank With seal & signature code
BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.
Page 2 of 2
Tender Notice No. - ………….
ANNEXURE - VIII PROFORMA FOR BANK GUARANTEE FOR EARNEST MONEY DEPOSIT (To be executed on non-Judicial stamped paper of appropriate value) B.G. No_____________
Date____________
1.
WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its Office at Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter referred as "The Owner/ Company" which expression shall unless repugnant to the subject or context includes its legal representatives, successors and assigns), has issued tender paper vide its Tender No. .............. for................................... (hereinafter called “the said tender”) to M/s............................ (hereinafter called “the said Tenderer(s)” which expression shall unless repugnant to the subject or context includes their legal representatives, successors and assigns) and as per terms and conditions of the said tender, the tenderer shall submit a Bank Guarantee for Rs.____________ (Rupees ___________________________ Only) towards earnest money in lieu of cash.
2.
We___________________ Bank having its branch office at _________________ do hereby undertake to pay the amounts due and payable under this guarantee without any demur merely on a demand from the Company stating that in the opinion of the company, which is final & binding, the amount claimed is due because of any withdrawal of the tender or any material alteration to the tender after the opening of the tender by way of any loss or damage caused or would be caused or suffered by the Company by reason of any breach by the said tenderer(s) of any terms and conditions contained in the said tender or failure to accept the letter of Intent/Agreement or that the amount covered under this Guarantee is forfeited. Any such demand made on the Bank by the owner shall be conclusive as regards the amount due and payable by the Bank under this Guarantee. However our liability under this guarantee shall be restricted to an amount not exceeding Rs........................... (Rupees……………. Only).
3.
We undertake to pay to the Company any money so demanded notwithstanding any dispute or disputes raised by the tenderer(s) in any suit or proceeding pending before any office, court or Tribunal relating thereto, our liability under this present guarantee being absolute and unequivocal. The payment so made by us under this bond shall be a valid discharge of our liability for payment there under. Our liability to pay is not dependant or conditional on the owner proceeding against the tenderer(s).
4.
The guarantee herein contained shall not be determined or affected or suspended by the liquidation or winding up, dissolution or change of constitution or insolvency of the said tenderer(s) but shall in all respects and for all purposes be binding and operative until payment of all money due or liabilities under the said tender are fulfilled.
5.
We _________________ Bank Ltd., further agree that the guarantee herein contained shall remain in full force and effect during the period that would be taken for the finalisation of the said tender and that it shall continue to be enforceable till the said tender is finally decided and order placed on Page 1 of 2
Tender Notice No. - ………….
the successful tenderer(s) and/or till all the dues of the Company under/or by virtue of the said tender have been fully paid and its claims satisfied or discharged or till a duly authorised officer of the Company certifies that the terms and conditions of the said tender have been fully and properly carried out by the said tenderer(s) and accordingly discharges the guarantee. 6.
That the Owner/Company will have full liberty without reference to us and without affecting this guarantee to postpone for any time or from time to time, the exercise of any of the power of the owner under the tender.
7.
Notwithstanding anything contained herein before, our liability shall not exceed Rs.__________ (Rupees________________________________ Only) and shall remain in force till __________unless a demand or claim under this guarantee is made on us within three months from the date of expiry, we shall be discharged from all the liability under this guarantee.
8.
We __________________ Bank, lastly undertake not to revoke this guarantee during its currency except with the previous consent of the Company in writing. We further undertake to keep this Guarantee renewed from time to time on the request of the Tenderer(s). Date: Corporate Seal of the Bank
......................Bank By its constitutional Attorney
Signature of duly Authorised person on behalf of the Bank With seal & signature code BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.
Page 2 of 2
Tender Notice No. - …………..
ANNEXURE - IX LIST OF STANDARDISED BANKS SCHEDULED PUBLIC SECTOR BANKS (INDIAN) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24
State Bank of India State Bank of Bikaner and Jaipur State Bank of Hyderabad State Bank of Mysore State Bank of Patiala State Bank of Travancore Allahabad Bank Andhra Bank Bank of Baroda Bank of India Bank of Maharashtra Canara Bank Central Bank of India Corporation Bank Dena Bank Indian Bank Oriental Bank of Commerce Punjab National Bank Punjab and Sind Bank Syndicate Bank Union Bank of India UCO Bank Vijaya Bank IDBI Bank (Twenty Four Banks)
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Tender Notice No. - …………..
LIST OF STANDARDISED BANKS SCHEDULED PRIVATE SECTOR BANKS (INDIAN) 1. 2. 3. 4. 5. 6. 7. 8.
ING Vysya Bank Axis Bank SBI Commercial & International Bank Ltd. ICICI Bank HDFC Bank Yes Bank Indus Ind. Bank Kotak Mahindra Bank (Eight Banks)
SCHEDULED FOREIGN BANKS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
American Express Bank Ltd. Bank of American NT & SA Bank of Tokyo Ltd. BNP Paribas Barclays Bank Plc Citi Bank NA Deutsche Bank AG. Hongkong and Shanghai Banking Corporation Standard Chartered Bank JP Morgan Chase Bank NA (Ten Banks)
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Tender Notice No. - …………..
ECS MANDATE FORM ELECTRONIC CLEARING SERVICES/ELECTRONIC FUND TRANSFER/INTERNET BANKING MANDATE FORM To National Aluminium Company Limited, NALCO Bhawan, Plot No. P/1, Nayapalli, Bhubaneswar - 751061 Dear Sir, Sub: Authorization for release of payment due from NALCO, Corporate Office, Bhubaneswar through Electronic Clearing Services (RBI)/ Electronic fund transfer (RBI/SBI)/ Internet Banking (SBI). Refer Order No……………..dt……………and/or Tender/Enquiry/Letter No……………..dt…………….. (Please fill in the information in CAPITAL LETTERS. Please TICK wherever it is applicable) 1. 2.
Name of the Party Address of the party
: :………………………………………… …………………………………………. ………………………………………… City:……………. Pin Code:………….. E-mail Id:
3.
Particulars of Bank: Bank Name Branch Name Branch Place Branch City Pin Code Branch Code MICR No. (9 Digits code number appearing on the MICR Band of the cheque supplied by the Bank. Please attach Xerox copy of a cheque of your bank for ensuring accuracy of the bank name, branch name and code number) Account Type ? Savings ? Current ? Cash Credit ? Account Number(as appearing in the Cheque Book)
4.
Date from which the mandate should be effective: I hereby declare that the particulars given above are correct and complete. If any transaction is delayed or not effected for reasons of incomplete or incorrect information, I shall not hold National Aluminium Company Limited responsible. I also undertake to advise any change in the particulars of my account to facilitate updation of records for purpose of credit of amount through RBI ECS/RBI EFT/SBI NET. Place: Date: Signature of the party/Authorized Signatory ----------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------Certified that particulars furnished above are correct as per our records. Bank’s Stamp: Date: (Signature of the Authorized Official from the Banks)
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Tender Notice No. - …………..
Annexure - X Social Accountability 8000 Compliance Format A.
Basic information Name of the organization Address
Telephone No Name of the Proprietor Nature of Business License Number and date of expiry Employees
Permanent
Casual
Badli Temporary Contracted
Staff (Total Number)
Workmen (Total Number)
B.
Information regarding Social Accountability
What is the minimum age required to join your organization?
What types of certificates (Like mark sheet, birth certificate) you keep with you?
Do you require to keep any kind of deposit inform of cash at the time of employment?
Yes/No
Do you provide safe & healthy work environment as per statutory requirement?
Yes/No
If directly not provided by you, do you get health & safety benefits from NALCO?
Yes/No
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___________ Years Original Copy / Xerox
Tender Notice No. - …………..
Are you certified for SA 8000? If Yes, please submit a copy of SA8000 Certificate along with this filled up questionnaire Have you undergone Code of Conduct Audit (COC Audit) in last 2 years ?
Yes/No
Yes/No
If yes, please submit a copy of Code of Conduct Audit Report along with this filled up questionnaire Have your sub-suppliers been certified for SA 8000?
Yes/No
Have your sub-suppliers undergone Code of Conduct Audit (COC Audit) in last 2 years?
Yes/No
Do you provide personal protective equipment(s) to your employees free of cost?
Yes/No
Do you provide safety training to your employees?
Yes/No
Do you ensure canteen facility for your employees?
Yes/No
If not, do you get the facilities from NALCO
Yes/No
What types of medical benefits you provide to your employees?
Do you allow trade union and collective bargaining in your organization? If no, how do you ensure freedom of expression?
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Yes/No
Tender Notice No. - …………..
Incase of non-performance of any employee, how do you deal with such situations?
What are the procedures of hiring/promotion/ remuneration in your organization?
Do you provide appointment letter to your employees?
Yes/No
Do you maintain a documented terms and conditions of employment?
Yes/No
Do you maintain a disciplinary procedure?
Yes/No
If no, how do you terminate your employee?
How do you ensure that your employees are not discrimination on the basis of cast creed, gender, religion, age and dieses?
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Tender Notice No. - …………..
How many shift you have?
_______ shifts
What is the official working time?
_______ hours
Which day is off day in your organization?
____________
In case, a person works in off day or holiday, how is he/she compensated?
Do you pay overtime to your employees as per law?
Yes/No
What is the lowest amount (salary/wage) you pay to your employees?
Rs._______/-
Is there any case of deduction in wage?
In case, it is yes, what are the general reasons for such deduction?
Is there any apprentice period in your organization?
If yes, what is the apprentice period in your organization?
Do you have any international certification
If yes, please specify
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Yes/No
Yes/No ___________ Yes/No
Tender Notice No. - …………..
Do you receive, handle or promote goods and/or services from supplier/subcontractors or sub-suppliers
Yes/No
Do you receive, handle or promote goods and/or services from supplier/subcontractors or sub-suppliers who are classified as home worker?
Yes/No
If yes, what steps you have taken to ensure that they get similar level of protection as afforded to directly employed employees?
Have you taken care to look into issues related to child labor Forced labor, health & safety, working hours and remuneration of your suppliers
Yes/No
We do hereby declare that our organization is committed to social accountability. We will promptly implement remedial/corrective actions identified against the requirement and promptly inform your organization. We also declare that the sub contractors/sub supplier’s performances are monitored by us. Moreover, we declare that if invited, we shall participate in awareness program as well as monitoring program organized by you. We declare that the above-mentioned information is correct.
Signature: Designation: Date
Seal of the organization
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ANNEXURE-XI PACKING, MARKING, SHIPPING AND DOCUMENTATION SPECIFICATIONS FOR INDIGENOUS MATERIALS
NALCO 1.0
General
1.1
This specification forms an integral part of the relevant PURCHASE ORDER, in addition to the specifications, drawings and instructions explicitly listed in the PURCHASE ORDER.
1.2
Seller shall strictly comply with all applicable prescriptions in the specifications. Lack of relevant information and/or documents shall not absolve the SELLER of his responsibilities and any loss arising out of non -compliance shall be to supplier’s account.
2.0
Project Name of OWNER, Project location and some other relevant information are as per Bid document.
3.0
Packing
3.1
The packing specifications incorporated herein are supplementary to the internal and external packing methods and standards as per current rules of IRCA goods tariff Part -I. All packing shall be done in such a manner so as to reduce volume as much as possible. Fragile articles should be packed with special packing materials depending on the type of materials.
3.2
Items shipped in bundles must be securely tied with steel wire or strapping. Steel reinforcing rods, bars, pipes, structural materials, etc. shall be bundled in uniform lengths and the weight shall be within the breaking strength of the securing wire or strapping.
3.3
All delicate surfaces on equipment/materials should be carefully protected and painted with protective paint/compound and wrapped to prevent rusting and damage.
3.4
All mechanical and electrical equipment and other heavy articles shall be securely fastened to the case bottom and shall be blocked and braced to avoid any displacement/shifting during transit.
3.5
Attachments and spare parts of equipment and all small pieces shall be packed separately in wooden cases with adequate protection inside the case and wherever possible should be sent along with main equipment. Each item shall be suitably tagged with identification of main equipment, item denomination and reference number of respective assembly drawing. Each item of steel structure and equipments shall be identified with two erection markings with minimum lettering height of 15 mm. Such marking will be followed by connection numbers in indelible ink/paint. A copy of the packing list shall accompany the material in each package.
3.6
All protrusions shall be suitably protected by providing a cover comprising of tightly bolted wooden discs on the flanges.
3.7
Wherever required, equipments/materials/instruments shall be enveloped in polyethylene bags containing silicagel or similar dehydrating compound.
3.8
All pipes shall be packed as under: a) b) c)
Upto 50mm NB in Wooden cases/crates. Above 50mm NB and upto 100mm NB in Bundles and the bundles should be strapped at minimum three places. Above 100mm NB in loose.
Individual cases/bundles must contain the pipes of same size and length. capped.
Ends should be
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3.9
ANNEXURE-XI
Pipes with threaded or flanged ends shall be protected with suitable caps/covers before packing. Line pipes shall be transported only on Flat bed trailers. Semi low bed/low bed trailer shall not be used. The trailers used for transportation of Line Pipes shall be equipped with adequate pipe supports, having as many round hollow beds as there are pipes to be placed on the bottom of the trailer bed. Total width of the supports shall be at least 10% of the pipe length. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection must be free from all nails and staples where pipes are in contact. The second layer and the following layers shall be separated from each other with adequate number of separating layers of protective materials such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of trailers used for transportation shall be covered by non -abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other positions such as reinforcement of the trailer body rivets etc. to prevent damage to the coated surface.
3.10
Detailed packing list in waterproof envelope shall be inserted in the package together with equipment/material. One copy of the detailed packing list shall be fastened outside the package in waterproof envelope and covered by metal cover.
3.11
The Seller shall be held liable for all damages or breakages to the goods due to the defective or insufficient packing as well as for corrosion due to insufficient protection.
3.12
Packaged equipment or material showing damage, defects or shortages resulting from improper packaging material or packing procedures or having concealed damage or shortages, at the time of unpacking shall be to the seller’s account.
4.0
Marking
4.1
Each package shall be marked on three sides with proper paints/indelible waterproof ink as follows: OWNER PROJECT DESTINATION Purchase Order No..................................................................................................... Net Wt.....................…………….... Kgs Gross Wt...................................... Kgs. Dimensions.......................................................X....................X...........................CM. Package No. (Sl. No. of total packages)......................................................................... Seller’s Name.............................................................................................................
4.2
Additional marking such as ‘HANDLE WITH CARE’, ‘THIS SIDE UP’, ‘FRAGILE’ or any other additional indications for protection and safe handling shall be added depending on the type of material.
4.3
Specific marking with paint for ‘SLINGING and ‘CENTRE OF GRAVITY’ should be provided for all heavy lifts weighing 5 Tons and above.
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PACKING, MARKING, SHIPPING AND DOCUMENTATION SPECIFICATIONS FOR INDIGENOUS MATERIALS
ANNEXURE-XI
4.4
In case of bundles/bags or other packages, wherever marking cannot be stenciled, the same shall be embossed on metal or similar tag and wired securely at two convenient points.
5.0
Shipment
5.1
Despatch of materials shall be made in accordance with the relevant terms of the Purchase Order. Any change in mode of transport shall be resorted to only after prior approval in writing. Seller shall ensure despatch of equipments/materials immediately after they are inspected and released. All consignments shall be booked in the name of Owner and not under self-basis.
5.2
Despatch by Road (a)
The Seller shall be responsible for despatch of materials on DOOR-DELIVERY basis through a reliable Bank -Approved transport company unless otherwise the transport company is named by OWNER/CONSULTANT.
(b)
The SELLER shall ensure with Transport Company the delivery of materials within a reasonable transit period. SELLER shall also obtain from transporter, particulars of Lorry Number, Transporter’s Challan Number, destination of lorry (if transshipment is involved), Transporter’s Agent at destination, if any, etc. and intimate same to General Manager (Projects), CPP, Nalco, Angul with copy to Resident Construction Manager at RITES, (respective Project Site).
5.3
Despatch by Rail
5.3.1
The SELLER shall be responsible for: (a)
Despatch by the shortest possible route. The Seller shall as far as possible, despatch the materials by the fastest goods train like QTS, Super Express Goods, etc. wherever such facilities exist.
(b)
Correct classification of goods and freight charges.
(c)
Obtaining clean Railway Receipts without any qualifying remarks. Should there be any restriction for movement by a particular route, the Railway authorities should be requested to move goods by the next alternative route, subject to prior consent of NALCO/RITES.
5.3.2
As “SMALLS” When the materials that are ready do not make up a wagonload by weight/volume or for minimum freight payable for a wagon the despatch should be affected as “smalls”. SELLER should obtain from the Railway, the particulars of wagon in which the “Smalls” have been loaded, station at which sealed, train Number and date/time of movement and transmit the same to the Resident / Visiting Inspector, General Manager (Projects), CPP-Nalco , RCM-RITES (concerned Site) for monitoring their movement.
5.3.3
As Wagon Loads Consignments, though of lesser weight, but otherwise constituting a “wagon load” by volume should be dispatched as “wagon load” paying the freight applicable to a minimum wagon load or at the smalls rate, whichever is advantageous, as per Rule-164 of IRCA Goods Tariff Part -I (Vol.I) When consignments call for full wagon(s), indents should be placed with the Railway Station concerned after predetermining accurately the type and number of wagons required. In case of Page 3 of 5
PACKING, MARKING, SHIPPING AND DOCUMENTATION SPECIFICATIONS FOR INDIGENOUS MATERIALS
ANNEXURE-XI
covered wagons, it should be ensured that the same are watertight. If a particular type of wagon is in short supply, request should be made to the Railway Authorities to supply the next suitable type of wagon. Suitable packing in the wagon shall be done, wherever necessary, to ensure maximum safety of the material in transit. When ODC packages are involved, the SELLER shall apply to the Railway Authorities with loading sketches showing overall dimensions and the wagon proposed to be utilized sufficiently in advance for obtaining movement sanction and to establish firm transportability. Copies of all such correspondence together with loading sketches should be sent to NALCO and Consultant RITES. ODC packages shall be loaded, packed and lashed strictly in accordance with the Railway Regulations. Should there be any delay/difficulty in obtaining the required wagon(s), the SELLER shall inform Resident Inspector and General Manager (Projects), CPP-Nalco , RCMRITES immediately giving details of the required number of wagons, type, carrying capacity, etc. and indent number so that the matter may be taken up with the Railway Authorities concerned. After despatch, SELLER shall obtain from the Railway Authorities, particulars of the wagon/train number, date of movement and destination junction for the particular train and furnish the same to General Manager (Projects), CPP-Nalco , RCM-RITES for follow-up action on movement, as may be necessary. After despatch of the equipment from dispatching station, if movement of the wagon is held-up due to improper/loose lashing resulting in shifting of the load and consignment is required to be readjusted/refixed the vendor shall be responsible to arrange for the same as per Railway requirements. Similarly, in case some infringement in dimensions of the loaded consignment is detected by Railway Authorities after its movement from despatching station and if it is required to be corrected either by adjustment of the load or by cutting a few protrusions the same shall be arranged by vendor at their cost. 5.4
Shipment by Air Wherever SELLER is instructed by OWNER/CONSULTANT to airfreight any material, the SELLER shall take prompt action for the same. Immediately after air shipment is effected, the Seller shall intimate by Fax / E-mail, the details of airway bill number and date, flight number, number of packages etc. to the Resident Inspector, Consultant RITES, General Manager (Projects), CPP-Nalco , Resident Construction Manager -RITES, (respective Project Site).
5.5
Destination The consignments should be despatched as indicated in bid document/Purchase Order.
5.6
Advance Information Immediately after a shipment is made, SELLER shall send advance information as to the particulars of materials, value, Purchase Order Number, date of despatch, railway receipt number, wagon number/goods consignment note number, truck number, name of transport company and their destination office/associate’s address etc./Airway Bill Number and flight details by way of Fax / E-Mail to Resident / Visiting Inspector, Consultant RITES, Resident Construction Manager- RITES, (respective Project Site) and NALCO.
5.7
Transmission of Despatch Documents Seller shall, within 48 hours of the despatch of the material depending upon the payment terms of the Purchase Order, either negotiate through OWNER’s Bankers or forward direct by Registered Post, the railway receipt/consignment note/Airway Bill to the Owner at project site accompanied by the original invoices, packing lists and challans.
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PACKING, MARKING, SHIPPING AND DOCUMENTATION SPECIFICATIONS FOR INDIGENOUS MATERIALS
ANNEXURE-XI
The SELLER shall be responsible for any delay in clearance of the consignment at destination and consequent wharfage/demurrage, if any, due to delay in transmittal of the Railway Receipt, Consignment Note/Air Way Bill. Copies of such despatch advise together with 2 copies of invoices and packing lists shall be simultaneously distributed to OWNER’s (HO & Site), Consultants (HO & Site) etc. 6.0
Transit Risk Insurance All equipments/ materials will be insured for transit risk by OWNER unless otherwise specified. The Insurance cover will be provided from warehouse - to - warehouse.
7.0
Despatch through Approved Transporters All materials must be despatched through OWNER/CONSULTANT approved transporters, list of which may be obtained from the OWNER’s/CONSULTANT’s nearest branch/regional office.
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