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NTPC Limited

(A Government of India Enterprise)

VINDHYACHAL SUPER THERMAL POWER PROJECT STAGE-III (2X500 MW)

SECTION VI
TECHNICAL SPECIFICATIONS FOR WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

(BOOK 1 OF 2) (MECHANICAL AND ELECTRICAL)


BIDDING DOCUMENT NO. : CS-2240-155C-2

NTPC Limited
(A Government of India Enterprise)

VINDHYACHAL SUPER THERMAL POWER PROJECT STAGE-III (2X500 MW)

SECTION VI
TECHNICAL SPECIFICATIONS FOR WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

(BOOK 1 OF 2) (MECHANICAL AND ELECTRICAL)


BIDDING DOCUMENT NO. : CS-2240-155C-2
(This document is meant for the exclusive purpose of bidding against this Bid Document No. / Specification and shall not be transferred, reproduced or otherwise used for purposes other than that for which it is specifically issued).

TABLE OF CONTENTS

TABLE OF CONTENTS
PART SECTION NO TITLE

BOOK 1 OF 2 : MECHANICAL & ELECTRICAL PART-A Sub Section- I Project Synopsis

Sub Section II : Scope of Supply & Services Intent of Specification IIA-01 PART-A Terminal Points & Exclusions IIB-01 IIC-01 PART-B PART-B PG Test Procedure Spares Scope

Sub Section III : Technical Parameters III-A IIIA-01 MECHANICAL System Parameters and Operation & Control Philosophy Wagon Tippler Brakes & Clamps Monorails and Hoists Chutes & Hoppers Belt Conveyor System Drive Equipment Belt Scale Dust Control & Miscellaneous System Ventilation System CHP Building Vibrating Screening Feeder Ring Granulator and VMS

IIIA-02 IIIA-03 IIIA-04 IIIA-05 IIIA-06 IIIA-07 IIIA-08 IIIA-09 IIIA-10 IIIA-11 IIIA-12 IIIA-13
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

MAIN CONTENTS

PAGE 1 OF 3

TABLE OF CONTENTS

PART

SECTION NO IIIA-14

TITLE Inline Magnetic Separator and Suspended Magnet Metal Detector Coal Sampling Unit Elevator Apron Feeder Side Arm Charger ELECTRICAL Motors LT Switchgear & Bus Duct HT Cables LT Power Cables Control Cables Instrumentation cables Illumination System Cabling, Earthing & Lightning Protection Transformers HT Switchgear Battery Battery Charger Control Panel Closed Circuit Television System (CCTV)

IIIA-15 IIIA-16 IIIA-17 IIIA-18 IIIA-19 PART-B PART-B III-B IIIB-01 IIIB-02 IIIB-03 IIIB-04 IIIB-05 IIIB-06 IIIB-07 IIIB-08 IIIB-09 IIIB-10 IIIB-11 IIIB-12 IIIB-13 IIIB-14

BOOK 2 OF 2 : CIVIL / QA&I / GTR / ECC / SPARES PART-B PART-B III-D IIID-01 CIVIL CHP System - Civil & Structural Works

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

MAIN CONTENTS

PAGE 2 OF 3

TABLE OF CONTENTS

PART

SECTION NO IIID-02

TITLE Foundation System and Geotechnical Data (Turnkey) QA & I SECTION Coal Handling Plant Motors LT Switchgear & Busduct LT Power Cables LT Control Cables Instrumentation Cables Station Lighting Cabling, Earthing & Lightning Protection Control Panels Programmable Logic Controller (PLC) Battery Charger HT Cables HT Switchgear Actuators Auxiliary Transformer Battery & Battery System Measuring & Instrumentation Closed Circuit Television System (CCTV) CHP System - Civil & Structural Works General Technical Requirements Erection Conditions of Contract List of Tender Drawings List of Mandatory Spares

PART-B

III-E IIIE-01 IIIE-02 IIIE-03 IIIE-04 IIIE-05 IIIE-06 IIIE-07 IIIE-08 IIIE-09

PART-B

IIIE-10 IIIE-11 IIIE-12 IIIE-13 IIIE-14 IIIE-15 IIIE-16 IIIE-17 IIIE-18 IIIE-19

PART-C PART-D PART-E PART-F

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

MAIN CONTENTS

PAGE 3 OF 3

PART - A

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

PART - A SUB-SECTION-I PROJECT SYNOPSIS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

CLAUSE NO.

PROJECT SYNOPSIS PROJECT SYNOPSIS

1.00.00

BACKGROUND Details of proposed Stage / Units Project name Project Stage No. of Units x capacity Vindhyachal STPP Wagon Tippler, Conveying & Crushing System Applicable for Stage-I (6x210 MW), Stage-II (2X500 MW) and for Stage-III (2X500 MW) Project setting up by Details of Existing Units : Stage-1: No. of units. : 6 Capacity : 210 MW NTPC Ltd.

Present Status : Units Commissioned Stage-2: No. of units. : 2 Capacity : 500 MW

Present Status : Units Commissioned Stage-3: No. of units. : 2 Capacity : 500 MW

Present Status : Units Commissioned 2.00.00 LOCATION AND APPROACH Project Location (i.) (ii) (iii.) Latitude and Longitude of project location Nearest Railway station Place :Vindhyachal

District :Sidhi State :Madhya Pradesh

North : 24 Deg 06' N East : 82 Deg 40' E

Shakti Nagar

Distance of project location from 2 KM (Approx.) the Railway station


VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-I PROJECT SYNOPSIS PAGE 1 OF 17

CLAUSE NO.

PROJECT SYNOPSIS Nearest Major Town Renukoot

Distance of the town from the 50 KM Project site Nearest Commercial Airport Varanasi

Distance of airport from the 220 KM project site Nearest Highway State Highway

Distance from nearest highway 2KM (aprox.) point to the site Vicinity plan Any other information: Vicinity plan of the project Further to the information given in this subsection , Bidders are advised to visit the project site and collect data on local site conditions

3.00.00

WATER Nearest Water Source Hot water discharge channel of Singrauli

Water requirement for the 230Cusec ultimate Stage (all the three stages) Proposed source/ arrangement to meet the water requirement : 4.00.00 Hot water discharge channel of Singrauli

COAL LINKAGE/AVAILABILITY AND TRANSPORTATION (a.) Coal Linkage/Availability Proposed source/ arrangement to meet the coal requirement : Coal Commitment/ Coal Link

MCL, CCL and Import tie-ups

The SLC granted linkage of 3.00 million tons per annum from MCL, CCL and Import tie-ups through Indian Railway System.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 2 OF 17

CLAUSE NO.

PROJECT SYNOPSIS The SLC granted linkage of 9.9 million tons per annum from NCL through MGR System. Any other information: Coal Requirement for Vindhyachal STPP Stage I, II & III is also being met from same coal source.

(b.) Coal Transportation Existing coal transportation Captive MGR system arrangement Proposed Coal transportation arrangement : Through Indian Railway System by laying additional track.

(c.) Coal Quality Parameters and Fuel Oil Characteristics The Coal quality Parameters and Fuel Oil Characteristics are enclosed as Annexures to this subsection. 5.00.00 METEOROLOGICAL DATA Data of Sidhi station is enclosed as Annexure to this subsection. 6.00.00 6.01.00 PLANT WATER SCHEME Condenser Cooling (CW) Water System It is proposed to provide recirculating type CW system with induced draft type cooling towers. Raw water for Stage - III of this project shall be pumped from the hot water (CW system) discharge channel of Singrauli Project of NTPC to Water Pretreatment Plant. The treated clarified water shall be pumped to the CW channels of Stage - III Circulating Water (CW) system at the upstream of cooling towers as make up to the system. It is proposed to operate the CW system at a C.O.C. of about 2.5 and CW side stream filtration and chemical treatment programme (using acid dosing and scale cum corrosion inhibitors dosing) shall be employed in addition to blow down of CW water to control the CW system water chemistry. The expected circulating water analysis is given in Annexure A-III of this sub-section. The CW blow water shall be tapped off from the discharge of CW pumps and led to a Service Water Tank. 6.02.00 Equipment Cooling Water (ECW) System (Unit & Station Auxiliaries) The plant auxiliaries of Steam Generator and Turbine Generator shall be cooled by Demineralised water (DM) in a closed circuit. The primary circuit DM water shall be cooled through plate type heat exchangers by Circulating Water tapped from CW

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 3 OF 17

CLAUSE NO.

PROJECT SYNOPSIS system in a closed secondary circuit The hot secondary circuit cooling water shall be cooled in the cooling towers and shall be returned back to the system.

7.00.00

ASH WATER SYSTEM It is proposed to operate the ash water system in a closed circuit at a C.O.C. of about 2.5. The ash water from the ash dyke shall be re-used after treating a part of the same in a side stream lime softening plant. During re-circulation mode, the make up to the ash water system (to compensate for the ash water blow down and evaporation loss) shall be supplied from the CW system blow down water. During initial operating stage of the project, when decanted ash water is not available from the dyke, the ash water system shall be operated in once through mode. The make-up water to ash water system shall be pumped from the raw water (from the discharge channel of Singrauli station) source, CW blow down water from the Service water tank and as well as from treated water from Central Monitoring Basin of liquid Effluent Treatment Plant. Considering total ash handling plant water requirement of 2500 Cu.M/hr for slurry formation during re-circulation mode operation, it is expected that about 2000 M3/hr of decanted ash water shall return to the ash handling system after accounting for evaporation loss. Considering a system blow down of about 350 Cu.M/hr from the system, raw water make up of 850 M3/hr shall be pumped from the service water tank which shall be CW blow down quality. About 30% of decanted ash water shall be treated in a side stream lime softening plant bay and treated water be led to ash water system. During once through mode operation, about 1000 M3/hr shall be pumped from the service water tank (CW system blow down quality) and balance 1500 M3/hr water shall be pumped from the raw water source (hot water discharge channel).

8.00.00

OTHER MISCELLANEOUS WATER SYSTEMS (a.) CW system blow down water shall be used for the plant service water requirement, Wash water for Air-preheaters and ESPs, dust suppression system of coal handling plant, make-up to fire water storage tanks and cooling water requirement of hydrogen generation plant. CW blow down water is estimated to be of the order of 1500 Cu.M/hr. The drinking water requirement shall be provided from the above mentioned Water pretreatment plant. It is proposed to provide two numbers of DM water storage tanks for Stage-III and these new sets of tanks shall be filled by extension of existing DM water pipelines of Stage-II. From the proposed DM water Storage tanks, DM water shall be pumped to meet the Steam Cycle make-up water requirement, makeup the hydrogen generation plant and makeup to the primary circuit of
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-I PROJECT SYNOPSIS PAGE 4 OF 17

(b.)

(c.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

PROJECT SYNOPSIS ECW system of unit auxiliaries by means of DM water make up pumps. In addition, separate set of boiler fill pumps shall be provided to fill the boiler from these DM water storage tank. DM Water required for regeneration of Condensate polishing Plant and resin transfer operation shall also be provided by these tanks. (d.) The service (wash water) collected from various areas shall be treated using oil water separators, tube settlers, coal settling pits etc. as per requirement and treated water from liquid effluent treatment plant shall be recycled back to the service water system for re-use. The excess service water from the service water tank/CW blow down pipe line shall be led to central monitoring basin for disposal. The quality of Clarified water, filtered (potable) water and DM water is given in the enclosed Annexure to this sub-section.

(e.)

9.00.00

CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT All structures and equipment of the power plant, including plant auxiliary structures and equipment, shall be designed for wind forces as given in the Technical Specification on Civil Works.

10.00.00

CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT All power plant structures and equipment, including plant auxiliary structures and equipment shall be designed for seismic forces as given in the Technical Specification on Civil Works.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 5 OF 17

CLAUSE NO.

PROJECT SYNOPSIS

COAL QUALITY PARAMETERS Sl. No. Description Unit Design Coal

ANNEXURE A- II -1 Range of 95% Range of Adequacy coal Supplies Worst Coal Best Coal 6 7

1 A. 1. 2. 3. 4. B. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

PROXIMATE ANALYSIS (As received basis) Total Moisture Ash Volatile matter Fixed carbon % % % % 20.00 30.00 21.00 29.00 22.00 35.00 19.00 24.00 17.00 24.00 23.00 36.00 23 - 16 36 - 23 18 - 24 23 - 37

ULTIMATE ANALYSIS (As received basis) Carbon Hydrogen Nitrogen Oxygen Sulphur Carbonates Phosphorous Total Moisture Ash Total Gross Value C% H2% N2% O2% S% CO3% P2% H2O% % % Calorific KCal/Kg 37.56 3.2 0.95 6.94 0.3 0.75 0.3 20 30 100 3700 52 80 32.30 2.9 0.55 6.25 0.3 0.6 0.1 22 35 100 3200 48 80 45.00 3.5 1.6 7.06 0.5 0.92 0.42 17 24 100 4400 60 80 3000 - 4500 48 62 80 30.4 - 46.90 2.8 - 3.6 0.55 - 1.6 6.25 - 7.06 0.3 - 0.5 0.6 - 0.92 0.1 - 0.42 23 - 16 36 - 23

Hard grove index YGP index mg/kg (minimum)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 6 OF 17

CLAUSE NO.

PROJECT SYNOPSIS COAL QUALITY PARAMETERS Sl. No. Description Unit Design Coal ANNEXURE A- II -1 Range of 95% Range of Adequacy coal Supplies Worst Coal 1 C. 1. 2. 3. 4. 5. 2 ASH ANALYSIS Silica Alumina Iron Oxide Titania Phosphoric Anhydride Lime Magnesia Sulphuric Anhydride Alkalies (By diff.) D. a) (SiO2)% (Al2O3)% (Fe2O3)% (TiO2)% (P2O5)% 59.6 24.6 10.2 1.07 0.18 58.6 25.6 11.2 1.17 0.1 62.5 22.7 8.62 0.80 0.48 58.1 63.0 26.1 - 22.2 11.5-8.32 1.2 0.82 0.1 - 0.5 3 4 5 Best Coal 6 7

6. 7. 8.

(CaO)% (MgO)% (SO3)%

3.2 0.6 0.25

2.08 0.9 0.15

3.3 0.5 0.4

1.78 3.5 0.9 0.5 0.12 - 0.43

9.

Na2O + K2O%

0.3

0.2

0.7

0.2 0.73

ASH FUSION RANGE (Under reducing atmosphere) Initial Deformation Temperature Hemispherical temperature Fusion temperature (IDT) C 1110 1050 1150 1000 - 1150

b)

1300

1250

1350

1200 - 1400

c)

1400

1400

1400

1400-1450

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 7 OF 17

CLAUSE NO.

PROJECT SYNOPSIS COAL QUALITY PARAMETERS Sl. No. Description Unit Design Coal ANNEXURE A- II -1 Range of 95% Range of Adequacy coal Supplies Worst Coal 1 E. a) 2 3 4 5 Best Coal 6 7

ASH FUSION RANGE (Under oxidising atmosphere) Initial Deformation Temperature Hemispherical temperature Fusion temperature (IDT) C 1200 1100 1250 1050 - 1250

b)

1350

1300

1400

1250 - 1400

c)

1400

1400

1400

1400-1450

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 8 OF 17

CLAUSE NO.

PROJECT SYNOPSIS ANNEXURE A II- 2 (Sheet 1 of 2) FUEL OIL CHARACTERISTICS Sl. No. Characteristics Heavy Furnace Oil IS-1593 1971 Grade HV 4.5% Max. 10280 (Typical) 66 deg C Low Sulphur Oil Heavy Stock (LSHS) Heavy Petroleum Stock (HPS)

1. 2.

Total sulphur content Gross calorific alue(KCal/kg) Flash Point (Min) (PMCC) Water content volume (Max) Sediment (Max) by

1.0% Max Of the orderof11,000 76 deg C

4.5% Max. Of the orderof 10,000 66-76 deg C

3.

4.

by 1.0%

1.0%

1.0%

5.

weight 0.25%

0.25%

0.25%

6.

Asphaltene content by weight (Max.) Kinematic viscosity Centistokes 50deg (Max) in 370 C

7.

8.

Ash Content by weight 0.1% (Max.) Acidity (inorganic) Pour Point 72Deg.C Sodium content Vanadium content Nil (Max.) -

0.05%

0.1%

9. 10.

Nil -

Nil 72 deg C

11. 12. 13.

Specific heat below pour point (KCal/Kg C)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 9 OF 17

CLAUSE NO.

PROJECT SYNOPSIS

ANNEXURE-A-II-2 (Sheet 2 of 2) LIGHT OIL CHARACTERISTICS (AS PER IS 1460-1974 WITH AMENDMENTS UPTO OCT.85) S.No. 1. Characteristics Pour Point (max) LDO 12 deg. C & 21 deg C for Winter and summer respectively.

2.

Kinematic viscosity in centistokes at 38 2.5 to 15.7 deg.C Waste content, percent by volume (max) Sediment percent by mass (max) Total sulphur percent by mass (max) Ash percentage by mass (max) 0.25 0.10 1.8 0.02

3. 4. 5. 6. 7.

Carbon residue (Rans bottom) percent by 1.50 pass (max.) Acidity in organic Flash point (Min.) a) Abel C, min b) PMCC OC, min. 66 Not worse than No.2 Not worse than No.2 Nil

8. 9.

10. 11. 12.

Acidity, total, mg of KOH/g (max.) Copper strip corrosion for 3 hours at 100C Total sediment mg per 100 ml max. = 1.0

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 10 OF 17

CLAUSE NO.

PROJECT SYNOPSIS

ANNEXURE- A-IV WATER ANALYSIS Sl. No. a) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Note : Constituent as mg per litre

COOLING WATER ANALYSIS Calcium Magnesium Sodium & Potassium Bicarbonates Chloride Sulphate Carbonate Silica Iron pH Value Turbidity CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 SiO2 Fe NTU 148.0 37.5 47.5 104.5 47.5 81.0 0 25.0 0.75 7.6 - 7.9 50

The C.W system is expected to operate at about 2.5 Cycles of Concentration. RAW WATER (MAKEUP TO ASH WATER SYSTEM) ANALYSIS Calcium Magnesium Sodium & Potassium Bicarbonates Chloride CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 34.0 15.0 19.0 46.0 12.0

b) 1. 2. 3. 4. 5.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

PAGE 11 OF 17

CLAUSE NO.

PROJECT SYNOPSIS ANNEXURE- A-IV WATER ANALYSIS Sl. No. 6. 7. 8. 9. 10. 11. 12. Constituent Sulphate Carbonate Silica Iron pH Value Turbidity o Temperature ( C) as CaCO3 CaCO3 SiO2 Fe NTU mg per litre 10.0 0 10.0 2.0 7.6 - 8.2 50 -500 43

Note : Raw water from hot water channel of Singrauli STPP. c) 1. 2. 3. 4. 5. 6. 7. . 8. 9. 10. 11. 12. CLARIFIED WATER ANALYSIS (PT-CW) Calcium Magnesium Sodium & Potassium Bicarbonates Chloride Sulphate Carbonate Silica Iron pH Value Turbidity Temperature (oC) CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 SiO2 Fe NTU 59.2 15.0 19.0 41.7 19.0 32.5 0 10.0 2.0 7.6 8.2 50 - 500 43

Note : At the outlet of clarifier of PT plant


VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

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CLAUSE NO.

PROJECT SYNOPSIS ANNEXURE- A-IV WATER ANALYSIS Sl. No. d) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Constituent as mg per litre

FILTERED WATER ANALYSIS (Drinking Water) Calcium Magnesium Sodium & Potassium Bicarbonates Chloride Sulphate Carbonate Silica Iron pH Value Turbidity CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 SiO2 Fe NTU 59.2 15.0 19.0 41.7 19.0 32.5 0 10.0 0.30 7.5 7.7 2

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

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CLAUSE NO.

PROJECT SYNOPSIS

ANNEXURE-A-IV ANALYSIS OF DM WATER TO BE USED FOR MAKE-UP WATER TO CONDENSER Sl. No. 1. 2. 3. 4. 5. Characteristics Silica (Max.) Iron as Fe Total hardness pH value Conductivity Value 0.02 ppm as SiO2 Nil Nil 6.8 to 7.2 Not more than 0.1 excluding the effects of free CO2

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

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CLAUSE NO.

PROJECT SYNOPSIS VICINITY PLAN

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

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CLAUSE NO.

PROJECT SYNOPSIS METEOROLOGICAL DATA PAGE 1 OF 2

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

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CLAUSE NO.

PROJECT SYNOPSIS PAGE 2 OF 2

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-I PROJECT SYNOPSIS

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PART - A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES

COAL HANDLING PLANT : WAGON TIPPLER, CONVEYING & CRUSHING PLANT 1.00.00 1.01.00 INTENT OF SPECIFICATION This specification is intended to cover the following activities and services in respect of all the equipment of CHP - Wagon Tippler, Conveying & Crushing Plant to be installed for Vindhyachal Super Thermal Power Project of the National Thermal Power Corporation Ltd.), completely covering the following activities and services in respect of all the equipment specified and covered under the specifications and read in conjunction with Scope of Supply & Services, Sub-section-III, Part-A, SectionVI of Technical Specification. (a.) (i) Detailed design and engineering of all the equipment and equipment system(s). Complete manufacture including shop testing/ type testing. Providing engineering data, drawings, Commissioning procedures and O & M manuals, etc. for the Employers review, approval and records. Packing and transportation from the manufacturers works to site including customs clearance/ port clearance, if required. Receipt, unloading, storage, preservation conservation and insurance of equipment at site. Fabrication, pre-assembly, (if any), erection, testing and putting into satisfactory operation of all the equipment including successful completion of facilities. Associated civil, structural, architectural and electrical works. Commissioning and Guarantee Tests. completion of facilities and Performance

(ii) (iii)

(iv)

(v)

(vi)

(vii) (viii)

(ix)

Furnishing of spares on FOR site basis and handing over to NTPC stores. Reconciliation with custom authorities, if applicable. Satisfactory conclusion of the contract.

(x) (xi)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES (b.) The equipment and services to be furnished and erected as required in this Technical Specification shall also meet all the requirements as stated General Conditions of Contract (GCC), Special Conditions of Contract (SCC) and Bid Form & Procedures which shall be considered as a part of this technical specification as bound herewith. The Contractor shall be responsible for providing all materials, equipment and services, specified or otherwise (unless specifically excluded) which are required to fulfill the intent of ensuring operability and the reliability of the complete system covered under this specification. It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation. Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Other manufacturers products may also be considered provided sufficient information is furnished so as to enable the Employer to determine that the products are equivalent or superior to those named. Contractor is requested to carefully examine and understand the specifications and seek clarifications, if required, to ensure that they have understood the specifications. Such clarifications should reach Employer at least 15 days before the scheduled date of the opening of the bid documents. The Contractors offer should not carry any sections like clarifications, interpretations and/or assumptions. If the Contractor 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 Contractor may also make alternative offers provided such offers are superior in his opinion. In which case, adequate technical information, operating feed back, etc. shall be enclosed with the offer, to enable the Employer 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 Employer 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.

(c.)

(d.)

(e.)

(f.)

(g.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES (h.) Any deviation or variation from the scope, requirement and/or intent of this specification shall be clearly defined under Attachment-6 Deviations of Section-VII of bid documents irrespective of the fact that such deviations/ variations may be standard practice or a possible interpretation of the specification by the Contractor. Except for those deviations/ variations covered under Attachment-6 Schedules which are accepted by the Employer before the award of the Contract, it will be the responsibility of the Contractor 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 submitted by the Contractor with his proposal under Attachment-6 Deviations shall be considered. Bids not complying with this requirement shall be treated as non-responsive and hence liable for rejection. The interpretation of the Employer in respect of the scope, details and services to be performed by the Contractor shall be binding unless specifically clarified otherwise by the Employer in writing before the Award of the Contract. Before submitting his bid, the Contractor should inspect and examine the site and its surroundings and should satisfy himself as to the nature of the ground and subsoil, the quantities and nature of work, materials necessary for completion of the work and their availability, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the Employer. For all the related buildings and facilities in Employers scope and not covered under the scope of Contractor, the Contractor shall furnish all the related input data/ details for preparation of Mechanical/ Electrical/ Civil Drawings within 45 days of award of contract. The sizes of various buildings/conveyor galleries tunnels indicated in the tender drawings and the parameters of equipments indicated in various sections of technical specifications are the minimum requirements of the employer. Any increase in these sizes or the parameters, if required to meet the system/maintenance/operational requirement shall be supplied by the Contractor without any extra cost implication to the employer. 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, structures, facilities and buildings etc. from damage. In case any damage occurs due to the activities of the contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be immediately made good by the contractor at his own cost to the satisfaction of the Employer. The contractor shall also take all necessary safety measures with specific reference to excavation in rock, at
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

(i.)

(j.)

(k.)

(l.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 3 OF 21

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SCOPE OF SUPPLY & SERVICES his own cost, to avoid any harm or injury to his workers and staff from the equipment and facilities of the power plant. (m.) 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 Employer in this regard. Further, Contractor shall plan and co-ordinate all his activities considering restrictions, if any, on free access to his work areas due to the rail traffic. After award of work, before finalising his layout especially the layout / levels of conveyors, cable / pipe routes and other services, the contractor shall carry out a site survey to identify the location & details of existing facilities that may interfere with his proposed facilities. The contractor shall suitably modify his layout / levels to prevent dislocation of existing facilities and any cost / time implication arising out of such modifications will be to his account. Contractor shall also be responsible to determine and obtain the necessary details at site as required for interfacing and interconnection with the existing system / facilities. If during the execution of works it is found that there is interference with the existing facilities / structures, the contractor shall revise his design / detailed drawings to clear the interference and shall provide all necessary measures for the safety of existing structures. No claim in terms of cost or relaxation in time shall be entertained for any redesign, rework and for safety measures provided. If at any stage of work, any dismantling or modification or relocation of any existing facility is required to be done to complete the work in Contractors scope and which has been agreed by the Employer, the same shall be done by the Contractor at no extra cost or time implication to the Employer. All such changes will be as per drawings and work plan approved by the employer. (o) Contractors Office & Store Buildings For his site office and covered store buildings, the contractor shall adopt preengineered / pre-fabricated constructions made of steel with single / double skin, insulated or uninsulated roof and wall coverings (fabricated out of permanently color coated metal sheets). Alternatively, contractor can adopt readymade Portacabin or similar construction. Contractor shall ensure that all such constructions are well engineered, neatly constructed and overall present a pleasing look.

(n.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES (p) Use of ash and ash based products In line with Gazette Notification on Ash Utilisation issued by MOEF and its amendment thereafter, contractor shall use ash and ash based products in works as specified in these specifications, drawings and as per instructions of the Engineer. He shall also use ash and ash based products in construction of his offices, stores, staff quarters and labour huts etc. He shall furnish a compliance report along with all details of use of ash and ash based products along with each bill. (q) Repair & Maintenance Facilities by the Contractor Contractor shall establish/set up at site suitable repair facilities for construction plant, equipment and machinery (like piling rigs, cranes batching plant, dewatering pumps etc.) In case of piling rigs, cranes, batching plant etc. he will also make arrangements/tie up with equipment manufacturers / suppliers for periodic overhaul/maintenance and for major breakdown, if any. He shall also keep adequate stock of spares at site for various plant, equipment and machinery to meet day to day requirements as recommended by the equipment manufacturer/suppliers or as instructed by the Engineer. Contractor shall deploy dedicated qualified, full time mechanical/electrical foreman/supervisors for manning the repair facilities as specified above.

1.02.00

Equipment and services covered under Wagon Tippler, Conveying & Crushing Plant Package are described in the following sub-sections : MECHANICAL III-A-01 : System parameters and Operation & Control Philosophy III-A-02 : Wagon Tippler III-A-03 : Brakes and Clamps III-A-04 : Monorails and Hoists III-A-05 : Chutes and Hoppers III-A-06 : Belt Conveyor System III-A-07 : Drive Equipment III-A-08 : Belt Scales III-A-09 : Dust Control & Miscellaneous Systems

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES III-A-10 : Ventilation System III-A-11 : CHP Buildings III-A-12 : Vibrating Screening Feeders. III-A-13 : Crusher and VMS III-A-14 : Inline Magnetic Separator and Suspended Magnet III-A-15 : Metal Detector III-A-16 : Coal Sampling Unit III-A-17 : Elevator III-A-18 : Apron Feeder III-A-19 : Side Arm Charger ELECTRICAL IIIB-01: Motors IIIB-02 : LT Switchgear & Bus Duct IIIB-03 : HT Cables IIIB-04 : LT Power Cables IIIB-05 : Control Cables IIIB-06 : Instrumentation cables IIIB-07 : Illumination System IIIB-08 : Cabling, Earthing & Lightning Protection IIIB-09 : Transformers IIIB-10 : HT Switchgear IIIB-11 : Battery IIIIB-12 : Battery Charger

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES IIIB-13 : Control Panel IIIB-14 : Closed Circuit Television System (CCTV) CIVIL III-D-01 : CHP System Civil and Structural Works III-D-02 : Foundation System and Geotechnical Data QUALITY ASSURANCE III-E-01 to E-19 : Quality Assurance and Inspection

1.03.00

In addition to the specifications of equipment / system indicated in various sections as above and General Technical Requirement attached at Part-C of the Specification and Erection Conditions of Contract attached at Part-D of the Specification shall also form part of this Technical specification. TENDER DRAWINGS The drawings listed in the specification forming part of the specification shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this package shall be as identified in these drawings and read in conjunction with the text of these specifications. These drawings are preliminary drawings for bidding purpose only and subject to changes that may be necessary during the detailed engineering.

1.04.00

1.05.00

In case of any conflicts / contradiction among various volumes / sections / annexures / chapters / appendices / tender drawings of bid documents, the same shall be referred to the Employer for clarifications whose decision shall be final and binding. No extra claims shall be allowed on this account. SCOPE The scope of (Coal Handling Plant) Wagon Tippler, Conveying & Crushing Plant 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, manufacture, shop fabrication, assembly, testing and inspection at manufacturers works, packing, dispatch, transportation, transit insurance, custom clearance etc. as applicable, delivery to site, unloading, handling and storage at site, insurance during storage, complete services of construction, including erection supervision, testing, inspection, commissioning and handing over to Employer and Guarantee testing including all associated electrical, civil, structural & architectural works as specified, unless specifically excluded as per Section Terminal Points & Exclusions.
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

1.06.00 1.06.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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CLAUSE NO.

SCOPE OF SUPPLY & SERVICES The scope of the contractor shall be deemed to include all such items which although are not specifically mentioned in the bid documents and/or in Contractors proposal but are needed to make the system complete in all respects for its safe, reliable, efficient and trouble free operation and the same shall be furnished and erected unless otherwise specifically excluded as per Section Terminal Points & Exclusions. The general description of the proposed system and the broad scope of work under the specification shall include but not be limited to as elaborated below : DESCRIPTION, SCOPE AND TERMINAL POINTS BRIEF DESCRIPTION OF PROJECT Vindhyachal Super Thermal Power Project consists of three Stages. Under Stage-I, six (6) generating units each of 210 MW capacity have already been provided and are under operation. Under Stage-II, two (2) generating units each of 500 MW capacity have already been provided and are under operation. Under Stage-III, two (2) generating units each of 500 MW capacity have already been provided and are under operation along with their auxiliaries and other facilities. Under Stage-I (6 x 210 MW units) of the project one (1) coal handling plant consisting of one (1) track hopper, 2000 MTPH coal conveyor system (with 100 % standby parallel stream) along with paddle feeders, crusher house, trippers etc. and one (1) no. 2000 MTPH capacity stacker cum reclaimer with associated reclaim conveyors have been provided. Under Stage-II (2 x 500 MW units) of the project one (1) coal handling plant consisting of one (1) track hopper, 1500 MTPH direct stream coal conveyor system (with 100 % standby parallel stream) along with paddle feeders, crusher house, trippers etc. and one (1) no. 1500/2000 MTPH Stacking / Reclaiming capacity stacker cum reclaimer with associated 2000 MTPH reclaim conveyors have been provided. An interconnection has been provided between Stage-I and Stage-II for stacking the crushed coal from Stage-I to Stage-II stockyard through TP-5, Conveyor 21. Similarly, the reclaim conveyors taking feed from both the stockyards of Stage-I and Stage-II can drop on to Stage-I or Stage-II conveying stream for onward transfer of coal to Boiler Bunkers. Under Stage-III (2 x 500 MW units) of the project one (1) coal handling plant consisting of one (1) track hopper, 1500 MTPH direct stream coal conveyor system (with 100 % standby parallel stream) along with paddle feeders, crusher house, trippers etc. and one (1) no. 1500/1500 MTPH Stacking / Reclaiming capacity stacker cum reclaimer with associated 1500 MTPH reclaim conveyors have been provided. An independent CHP - Wagon Tippler, Conveying & Crushing Plant of 1400 TPH rated (guaranteed) capacity is proposed for feeding existing conveyor stream of Stage-I and feeding stockyard of Stage-II. Coal handling plant consisting of two (2)
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

1.06.02

2.00.00 2.01.00 2.01.01

2.01.02

2.01.03

2.01.04

2.01.05

2.01.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SCOPE OF SUPPLY & SERVICES nos. wagon tipplers, 1400 TPH coal conveying system (with 100 % standby parallel stream) along with crusher house are proposed to be installed along with their auxiliaries and other facilities.

2.01.07

Brief description of proposed Coal handling Plant This shall be read in conjunction with Coal Flow Diagram and the General Layout Plan enclosed else where in this specification. (i) Indian Railway (IR) rakes consisting of Box-N wagons shall transport coal to the power plant. The coal received form Box-N wagons shall be unloaded in underground RCC hoppers by means of Rota side wagon tipplers. Each wagon tippler hopper shall have a loading capacity of minimum three (3) wagon load of coal i.e. 180 Te. Two (2) such Rota side wagon tipplers (WT-1 & WT-2) are to be employed for unloading IR Coal rake. Side arm chargers are envisaged for placement of wagon on the tippler table & removal of empty wagon from tippler table after tippling. Clear access shall be provided for movement of pay loaders/ bulldozers on the hopper grating of wagon tipplers. Gratings over wagon tippler hopper shall be placed and designed accordingly. Apron feeders are employed under each wagon tippler for extracting coal from wagon tippler hopper and feed onto underground reclaim conveyors. Two (2) No. wagon tipplers (WT-1 & 2) alongwith Two (2) Nos. Apron feederAF-1 & 2 shall be provided to unload coal from Box-N wagons. Apron feeder AF-1, receiving coal from WT-1 shall drop coal on to either conveyor 37A or 37B at Junction Tower JT-1 and Apron feeder-AF-2 receiving coal from WT-2 shall also drop coal on to either conveyor 37A or 37B at Junction Tower JT-1. The rated capacity of Apron Feeder shall be 1200 MTPH and Conveyors shall be 1400 MTPH. However rated capacity of existing / extended conveyor 21 is 2000 MTPH. Conveyor 37A/37B receiving coal from Apron Feeder AF-1 or AF-2 at JT-1 shall feed coal to conveyor 38A or 38B at Junction Tower JT-2. Suspended magnets (SM-1 and SM-2) shall be provided on Conveyor 37A/37B at JT-2 for removal of tramp Iron pieces. Further at Junction Tower, JT-2 provision shall be kept for Conveyor 37A/37B dropping coal on to future conveyor of Stage-IV. Conveyor 38A/38B shall feed coal to crusher house CH-WT via Pent House (PH). Metal detectors MD-1 and MD-2 shall be provided on Conveyors 38A/38B to detect metallic tramps present in the as received coal. Two numbers Belt Scale (BS-1 & BS-2) shall also be provided, one each on Conveyor 38A and 38B for measurement of coal flow rate. Further Conveyor 38A/38B shall have facility for manual stone picking, at a suitable location after PH. In line magnetic separators (ILMS-1 & 2) shall be provided on

(ii)

(iii)

(iv)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES Conveyor 38A/38B head end at crusher house for removal of metallic ferrous tramp from as-received coal. (v) Coal from each incoming Conveyor 38A/38B to Crusher House (CH-WT) will pass through a set of dedicated crushers i.e. Crushers (CR-1 & CR-2) respectively. There shall be a combination of Rod Gate and Rack & Pinion Gate provided in the inlet chute of each vibrating grizzly screen. In Crusher house (CH-WT), coal from incoming Conveyor 38A will pass through one (1) number (dedicated) Vibrating Screening Feeder (VSF-1) and one (1) number (dedicated) crusher (CR-1) respectively. Similarly coal from incoming conveyor-38B will pass through one (1) number (dedicated) vibrating screening feeders (VSF-2) and one (1) number (dedicated) crushers (CR-2) respectively. This shall permit maintenance of equipment, hopper and chutes in one stream without effecting the operation of other stream. The crusher shall be of ring granulator type. Coal sampling unit (CSU-1) shall be provided to sample the coal of (-)250mm size. Further, a passenger cum goods elevator (EL-1) as specified elsewhere shall also be provided in Crusher House (CH-WT). Each of the two (2) Vibrating Screening Feeder shall be of 1400 TPH capacity. Each of the two (2) ring granulator shall be of 1400 MTPH capacity which shall crush coal to (-) 20mm size. Both the screened coal below 20mm size and crushed coal shall be discharged on to Movable Belt Feeders (BF-1 & BF2) placed below the crusher floor for discharging crushed coal on to either Conveyor 39A or 39B. (vii) At Junction Tower JT-3, Conveyor 39A/39B shall drop coal onto either existing Conveyor 3A or 3B of Stage-I for bunkering of coal or shall drop coal on to Conveyor 39A/39B itself. At Junction Tower JT-4, Conveyor 39A/39B shall drop coal onto extended Conveyor 21 of Stage-II for stocking coal at Stage-II Stockyard through existing Transfer Point TP-8. Existing Transfer Tower TP-5, of stage-II, shall be modified for extension of conveyor-21 to Junction Tower JT-4 to receive coal from conveyor 39A/39B. Existing Conveyor gallery of Conveyor 3A/3B, of Stage-I, shall be suitably modified for incorporation of new Junction Tower JT-3 and for receiving coal from new conveyor 39A/39B. Provisions shall be made on conveyor 39A/39B to receive coal from future conveyor 60A/60B through future TP-49.

(vi)

(viii)

(ix)

(x)

(xi)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES DETAILED SCOPE Underground wagon tippler hoppers, underground Junction Tower, JT-1, JT-2 underground tunnels and pent house (PH), complete with civil, structural, architectural and electrical works including machinery hatches, steel grating (over hopper portion), removable chequered plate covers over openings in machinery hatches for handling underground equipment in wagon tipplers and for all other buildings, structure over machinery hatches equipment handling facilities for feeders below wagon tippler and below machinery hatches, hand rails and other equipment/systems such as DS system, ventilation system, drinking water system, drainage system etc. as specified elsewhere in the specification. However, rails and its fixing over wagon tipplers are excluded from Contractors scope but fixation of rails near wagon tippler table is in Contractors scope. Two (2) nos. Rota side Wagon Tipplers alongwith hydraulically driven side arm charger and electronic weighing bridges including all accessories, electricals and associated civil structural & architectural works. Two (2) nos. Apron Feeders alongwith dribble Conveyor complete with drives including all accessories, electricals, supporting structures, approach/ maintenance platform and associated civil & structural works etc. Conveyors 37A/37B complete with tunnel alongwith its supporting structures, short supports, stringers, deck plates, Conveyor foundations, drive motors drive units, Pulleys, Idlers, take-ups, take-up structures, internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes all electrical etc. including all civil structural and architectural works and their associated foundations. Conveyor 38A/38B with tunnel, conveyor gallery along with its supporting structures, short supports, stringers, deck-plate, seal-plate, conveyor foundations, drive motors, pulleys, idlers, gravity take ups, take up structure, internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for tunnel, conveyor gallery, gallery supporting trestle and their associated foundation etc. Conveyor 38A/38B shall have facilities for manual stone picking arrangement at an appropriate location after the pent house (PH). Belt Conveyors 39A/39B complete with conveyor galleries, conveyor supporting structures, fixed trippers, short supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units, pulleys, idlers, gravity take ups take up structures internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations etc.

2.02.00 2.02.01

2.02.02

2.02.03

2.02.04

2.02.05

2.02.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

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SCOPE OF SUPPLY & SERVICES Provisions shall be made on conveyor 39A/39B to receive coal from future conveyor 60A/60B through future TP-49 Extension of existing Conveyor 21 of Stage-II, from existing transfer point TP-5 to Junction Tower JT-4 complete with ground conveyor gallery, conveyor supporting structures, short supports, stringers, deck plates, conveyor foundations, idlers pullchord switches, belt sway and zero speed switches etc. for extended length of conveyor, electro-hydraulic thruster brakes modification of take-ups and take-up structure as required check for adequacy of Belt and Drive Unit and all electrical, civil, structural and architectural works and their associated foundations for extended conveyor as required. Modification of existing conveyor gallery of conveyor 3A/3B, of Stage-I, for incorporation of junction tower JT-3 including accessories as described elsewhere. Modification of Conveyor 3A/3B and its gallery shall also include provision of chute work, skirt board over existing Conveyor 3A/3B for receipt of Coal from Conveyor 39A/39B etc. One (1) number Crusher House (CH-WT) complete with all civil, structural, architectural and electrical works etc accommodating two (2) nos. Ring Granulators and associated Vibrating Screening Feeders, R&P and Rod Gates etc., passenger cum goods elevator, conveyors, chute work alongwith movable belt feeder, monorails & hoists, hoist maintenance platform, external and internal staircases, hand rails and other equipments such as coal sampling unit, dust suppression, dust extraction system, elevator etc. as specified elsewhere. Two (2) nos. Vibrating screening feeders (in crusher house CH-WT) to feed the coal to crushers complete with drives, dust hood, all mechanical, electrical accessories and supporting structures etc. Two (2) nos. ring granulators complete with drives, accessories all mechanical, electrical, civil & structural works, including crusher supporting foundations, vibration isolation system with springs & viscous dampers, vibration monitoring system etc. Two (2) sets of Gates each comprising of one rod gate and one actuator operated rack & pinion gate at inlet to each of the vibrating screening feeder feeding coal to crushers complete with drives, all mechanical, electrical, structural works etc. Junction Tower JT-1 & JT-2 (along with under ground RCC structures), JT-3 and JT -4, tunnel complete with all civil, structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, external/internal staircases as required., etc. Junction Towers (JT-3 and JT-4) shall have debris disposal chute up to the ground floor. Underground Junction Tower JT1& JT-2, shall be provided with machinery hatch with removable chequered plates for handling under ground equipment, internal stair case alongwith monorails, hoists/chain pulley blocks.
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

2.02.07

2.02.08

2.02.09

2.02.10

2.02.11

2.02.12

2.02.13

2.02.14

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SCOPE OF SUPPLY & SERVICES At Junction Tower JT-2, provision shall be kept for dropping coal from conveyor 37A/37B to either of Conveyor 38A/38B or to future Stage-IV conveyors. Moving head alongwith take-up arrangement of conveyor 37A/37B shall be accordingly designed. All mechanical and electrical equipment, to be housed in Junction Tower JT-1, JT-2, JT-3 and JT-4 including coal feeding chutes, monorails, hoists, maintenance/ operating platforms inside the JTs & maintenance platforms at various levels for take-up including support beams. Existing Transfer Point TP-5 alongwith conveyor-21 & its gallery, of Stage-II, to be modified for extension of conveyor-21 to take coal feed from JT-4. Complete chute work along with chute block switches and actuator operated flap gates, mobile discharge pulleys and belt feeders as applicable in all Junction Towers and crusher house between various conveyors. One (1) No. passenger cum goods elevator with drives, all electrical, mechanical, civil, structural & associated foundation works, accessories and electrical to serve various floors of the Crusher House (CH-WT). One (1) coal sampling unit to sample the coal of (-) 250mm size with all drives, equipment, electrical, mechanical, civil, structural and associated foundation works, accessories etc. to be in crusher house (CH-WT) Adequate number of ventilation equipment for ventilating the under ground portion of wagon tippler complex, underground tunnel of Conveyor 37A/37B, Conveyor 38A/38B, underground Junction Towers JT-1 & JT-2 complete with all mechanical, electrical, civil and structural works and associated foundations. Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with all mechanical, electrical, accessories, civil and structural works. Exhaust fans to be provided in all battery rooms, all toilets complete with electrical, civil & structural works etc. Exhaust fans along with required ducting shall also be provided for all underground Structures/Junction Towers. Air conditioning of Main control room and office room in control building, MCC room, wagon tippler control rooms, office room in wagon tippler control building, complete with all electrical, civil & structural works etc. Minimum two (2) Nos. sump Pump for JT-2 complete with motors, local control panel, level switches, individual discharge piping with fittings and valves to nearest plant drain including pipes etc. upto disposal point.

2.02.15

2.02.16

2.02.17

2.02.18

2.02.19

2.02.20

2.02.21

2.02.22

2.02.23

2.02.24

2.02.25

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 13 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES Two (2) Nos. In-line Magnetic Separators on Conveyor 38A/38B & two (2) nos. suspended magnets on Conveyor 37A/37B complete with reject chutes & reject trolleys for ILMS, supporting arrangement, and all mechanical, electrical, civil, structural works and accessories. Four (4) Nos. Electronic Belt weighers complete with all mechanical, supporting arrangement, electrical, and accessories on conveyors 38A/38B & 39A/39B. Four (4) Nos. Metal Detectors complete with all mechanical, electrical, civil, structural works and accessories on Conveyor 38A/38B & 39A/39B. One (1) No. belt vulcanizing machine of adequate size complete with all mechanical, electrical, accessories and consumables for one year consumption. Further, belt jointing facilities as specified shall be provided. Complete dust suppression system for control of fugitive dust in wagon tippler hoppers, junction towers, crusher house complete with pump house, water tanks, pumps, drives, hoisting arrangements, piping, valves etc. electrical, accessories, civil, structural and architectural works as briefly specified below : a. Plain water dust suppression around the wagon tippler top through spray nozzles. Complete dry fog type dust suppression system at all Junction Towers, Crusher House both at conveyor discharge and loading points including all electrical and accessories. Water Pump house & water tanks for dust suppression/ extraction, service water, cooling water and potable water system.

2.02.26

2.02.27

2.02.28

2.02.29

2.02.30

b.

c.

2.02.31

Service water, potable water system and cooling water system for complete coal handling plant. Complete dust extraction system for control of fugitive dust in crusher house with complete pumps, drives, hoisting arrangements, piping, valves etc. electrical accessories, civil, structural and architectural works. Cooling water system for scoop couplings, as specified elsewhere in the specification. Monorails and electrically operated hoist blocks as well as hand operated chain pulley blocks for servicing/installation/easy replacement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment from ground level to their locations and vice-versa.

2.02.32

2.02.33

2.02.34

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 14 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES All buildings in contractors scope shall be complete with all electrical, civil, structural, architectural works, cable trenches, fire safety walls, foundation, earth mat, fencing, earthing for transformers. All cables, duct banks, trenches, cable trestles shall be complete with associated civil/ structural work and necessary civil foundations. Drainage of all CHP buildings, wagon tippler hoppers, tunnels, conveyor galleries including all civil & structural works as detailed out elsewhere in the specification. All equipment/fittings, supporting structure, along with insert plates, bolts, accessories, MS sleeves, base plates, grouting as may be required and proper alignment etc. Complete unused set of all special tools and tackles, which are necessary or convenient for erection, commissioning and overhauling of any equipment, covered under the scope. First fill of all consumables e.g.; oils and lubricants for one year toppings requirements. Preservative shop coating, final painting of all structures and equipment under the scope. All inserts, anchor bolts, foundation bolts for Contractors equipment, platforms etc. All necessary grouting & finishing of the floor after welding at all such pockets & else where is in Contractors scope. Electrical System / Equipment Unless specifically excluded in clause no. 2.04.00 contractors scope of work shall include all electrical works as required for putting into successful operation of the Wagon Tippler Crushing & Conveying Plant covered under this specification. The sizing of the various equipments shall be as defined in the specification.

2.02.35

2.02.36

2.02.37

2.02.38

2.02.39

2.02.40

2.02.41 2.02.42

2.02.43

2.02.43.01

SWITCHGEAR 6.6KV and 415V Switchgear/motor control centers (as shown in electrical single line diagram), busduct (as applicable), distribution boards, One (1) AC fuse board in each MCC room, local motor starters as required for plant and equipment. In addition, 2 nos. of 125A switch fuse feeders (total load 50 KVA) shall be provided on each LT MCC-IA & MCC-IB, for employers use. Outgoing feeders shall be segregated stream wise and equally distributed on each bus section of the MCC.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 15 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES TRANSFORMERS Transformers as indicated in electrical single line diagram.

2.02.43.02

2.02.43.03

MOTORS Motors along with couplings and coupling guards for all rotating auxiliaries covered under this package. All motors shall be with cable glands & lugs.

2.02.43.04

CABLES HT & LT Power, Control & Instrumentation cables, HT & LT trailing cables and any special cables required for connection between equipment/devices in Contractors scope.

2.02.43.05

CABLING, EARTHING AND LIGHTNING PROTECTION (a) i) Cable trays with supporting structure, trenches, duct banks etc. as required for the cables to be supplied by the Contractor for the complete coal handling system. Cabling viz., cable laying along with cable accessories for cables supplied by the contractor. Cable trestle in Contractors scope is as marked in the General Plant Layout drawing, however, exact coordinates shall be finalized during detail engineering.

ii)

iii)

(b)

Grounding and lightning protection for the plant and equipment under Contractors scope along with its interconnection to the nearest employers earth grid at two points.

2.02.43.06

ILLUMINATION SYSTEM Illumination system for complete internal and external lighting of associated plant, equipment, buildings and roads under Contractors scope.

2.02.43.07

220V DC System for the complete WT Crushing & Conveying plant shall be provided by the contractor complete with Batteries, chargers and DCDB. Two (2) nos. DCFB shall be provided at each location of DC requirement which shall receive 220V DC from the main CHP DCDB. Emergency stop Push Button for all HT and LT motors. Closed Circuit TV system as specified elsewhere.

2.02.43.08 2.02.43.09

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 16 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES CONTROL SYSTEM Contractor shall provide independent PLC based control system consisting of control Desk, PLC Panels, I/O racks along with its power supply arrangement etc. for the control of entire Coal handling plant except for wagon tipplers.

2.02.43.10

2.02.44

INSTRUMENTS (a) All the Instruments as indicated in enclosed flow schemes/diagrams and relevant tender drawings, corresponding Mechanical sections and meeting redundancy and other requirements specified under technical specifications are to be provided as a minimum. All Instruments which are Integral to equipment required for control, monitoring and operation of the equipment/plant/ Systems are to be provided. All the instruments shall be provided by the Contractor to meet actual system requirements subject to Employers approval. Further, all the instruments / equipments including transmitters, transducers temperature elements, switches which are required to implement the control philosophy as specified in corresponding mechanical sections shall also be provided by the contractor.

(b)

(c)

2.02.45

ELECTRICAL BUILDINGS i) One (1) No. switchgear building near wagon tippler to house Contractors MCC-IA, 220V DC battery charger panel, MLDBs & Welding DBs as required, etc. in the ground floor. Also a separate room to accommodate Contractors 220V DC battery shall be provided in the ground floor. An independent Air conditioned room for accommodating Contractors PLC panels, I/O panels. UPS and programming OWS as per the PLC configuration diagram in the first floor shall be provided. Two (2) nos. 6.6/0.433 KV Transformers are to be located by the side of the building. An Air conditioned office room (5m x 5m) shall be provided at first floor and a control room with view balcony to house operator work station. One (1) No. Switchgear building near crusher house to accommodate Contractors 6.6KV switchgear, MCC-IB, MLDBs, Welding DB as required, TR panels for ILMS/SM, 24V DC battery and chargers etc. Further, the ground floor shall have a separate air conditioned 6mx5m room to accommodate R I/O panels. Two (2) Nos. of 6.6/0.433KV, transformers are to be located by the side of this building. Main CHP Control desk, processor panels, LVS, I/O panels, UPS etc. shall be provided I the existing HP control room of Stage-II by suitably extending the building by 6x8m. The extended portion should be air control.
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

ii)

iii)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 17 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES iv) One (1) No. control room building for Wagon tippler-2 controls to house UPS etc. and an office room (5m x 5m) at the ground floor and a control room with view balcony to house Operator work station with control desk, R I/O panel etc at the first floor. Office rooms and control room shall be air conditioned. The rooms shall be suitably located to have good view of the Wagon tippler operation.

2.02.46 2.02.46.01

CIVIL The work to be performed under this specification consists of providing all labour, materials, construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractors supervision and in strict accordance with the drawings and specifications. The nature of work shall generally involve earthwork in excavation including controlled blasting & very deep underground excavation, extensive de-watering, shoring and strutting, sheet piling, back filling around completed structures and plinth protection, area paving , disposal of surplus excavated materials, piling, concreting including reinforcement and form work, brick work, fabrication and erection of structural / miscellaneous steel works, inserts, architectural items & finishes such as plastering, painting, flooring, doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently colour coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers, laying and testing of water pipes, sanitation, water supply, drainage, damp proofing, water proofing and other ancillary items. The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations including vibration isolation systems, grounding, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer galleries, trestles, penthouse, wagon tippler, underground tunnels, crusher house, junction towers, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries) and all other civil, structural and architectural works associated with the complete Coal Handling Plant. Scope of the Contractor shall also include supply and laying earthing mat all around the periphery of buildings, structures, and outdoor equipments, as per the approved drawings. The analysis design and detailed drawing for the structures like wagon tipplers, tunnels, etc. coming below the railway track shall be got approved by the Contractor from the Concerned railway authority before taking up construction. All necessary payment for above work shall be made by the contractor to the Railway authority. The work shall also involve arranging construction water from underground sources, storage in underground/ overground tanks and taking the water to construction site through pipelines by pumping or by road tankers etc., including all necessary accessories, tools & tackles etc. Access roads (concrete, 4m wide) to all buildings/facilities (in Contractor Scope) will be in the Contractors Scope.
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

2.02.46.02

2.02.46.03

2.02.46.04

2.02.46.05

2.02.46.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 18 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES TERMINAL POINTS Broad terminal points for WT crushing & conveying plant have been indicated in the tender drawings. Within these terminal points, all equipment and services, civil, structural and architectural works, electrical distribution, piping network etc. as required for the plant will be furnished and erected by the contractor unless specifically excluded as follows:

2.03.00

2.03.01

Water supply connections for dust suppression, dust extraction, service water system, potable water shall be provided at suitable location near proposed CHP Package by the employer, details of which shall be given to the successful bidder. Further network of piping including all pumps, tanks, necessary accessories, supports and fittings etc. for distribution of potable water, water for dust suppression and service water system in all JTs, crusher house, control rooms, MCC rooms, toilets, wagon tipplers etc. shall be under the scope of the contractor. Electrical Terminal Points Employers CHP 6.6KV Switchgear.

2.03.02

2.03.03

Civil The trunk sewer lines are proposed to be installed by the employer. The sewerage from all the facilities planned under the contract shall be connected by the Contractor to this trunk sewer network.

2.04.00 2.04.01

EXCLUSIONS Supply, laying and fixing of rail over wagon tippler is excluded from the scope of this Contract. However, necessary pockets for fixation of rails on wagon tippler shall be in the scope of Contractor. Site leveling is excluded from the scope of this Contract. However site clearance i.e. removal of vegetation including bushes and trees etc. shall be the responsibility of the Contractor. SYSTEM DESIGN BASIS The rated capacity of the CHP shall be 1400 TPH. The mechanical and structural / civil system shall be designed for 1540 TPH capacity and round the clock operation with both the streams operating simultaneously. Following shall be considered while designing the CHP: a) The Coal delivered to the power station shall be of size 250 mm & below. However occasionally 1-2% coal of 400 mm lump size may also be encountered.

2.04.02

3.00.00 3.01.00

3.02.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 19 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES b) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary between 12% to 15%. However for design purposes, moisture content of 20% shall be considered. Due to open cast method of mining involved, the coal may contain shale and sand stone as high as 20%. Also occasionally metal pieces like broken shovel teeth, brake shoe, wires etc., may also come alongwith coal from open cast mine. The coal as received shall contain varying percentage of fines. Coal with such fines may tend to form adhesive lumps, particularly during monsoon when surface moisture is at its maximum value. The sizing and selection of the vital equipment viz. crushers, vibrating screening feeders, feeders etc. covered under the system shall be based on the above characteristic of coal and operating conditions. Contractor shall ensure that equipment/ system efficiency shall not be affected particularly during monsoon when surface moisture is at its maximum value.

c)

d)

e)

3.03.00

For the purpose of volumetric computation, the bulk density of the coal shall be taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. the above bulk density shall be considered. For all other purposes viz. for stresses/ load on structures, Loading on Apron feeder table, loading on VSF tables, sizing of actuators for flap gates, R&P gates, calculations of plugged chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3. All mechanical, and structural / civil system design shall consider simultaneous running of both the streams at rated load starting of one stream with the other stream in standstill condition as well as starting of one stream with the other stream in operation. Coal Flow paths For the purpose of conducting guarantee test coal, flow is divided into following coal flow paths. (i) Flow Path IA (Direct Stream): Apron feeder AF-1 taking feed of incoming coal from Wagon Tippler-WT-1 and discharging crushed coal into existing conveyor 3A/3B of Stage-I including all intermediate Conveyors and equipment. (ii) Flow Path IB (Direct Stream) : Apron feeder AF-2 taking feed of incoming coal from Wagon Tippler-WT-2 and discharging crushed coal into conveyor-21 of stage-II including all intermediate Conveyors and equipment. (iii) Further for the purpose of Guarantee tests Conveyor 21 alongwith all associated equipment shall also be considered.

3.04.00

3.05.00 3.05.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 20 OF 21

CLAUSE NO.

SCOPE OF SUPPLY & SERVICES Performance and Guarantee Tests shall be conducted in such a way that all the conveyors in both the streams are covered. For this purpose it may be necessary to repeat the Performance & Guarantee tests until all the conveyors are covered. Combination of conveyors to be tested shall be at the discretion of the Employer. The maximum liquidated damages calculated as above, for any one of the paths shall be levied on Contractor. Contractor shall also demonstrate that all intermediate equipments can perform as per specification and design requirement. Simultaneous operation of both the paths in conveyor streams shall also be demonstrated during PG Test. Performance and Guarantee tests have been elaborated elsewhere in the specification.

3.05.02

3.05.03

3.05.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIA-01 SCOPE OF SUPPLY & SERVICES

PAGE 21 OF 21

PART - A SUB-SECTION-IIB-01 PG TEST PROCEDURE

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

CLAUSE NO.

GUARANTEE TEST PROCEDURE

1.00.00

STANDARD GUARANTEE AND ACCEPTANCE PROCEDURE FOR COAL HANDLING PLANT SYSTEM FACILITIES

TESTS

AND

TESTING

1.01.01 1.01.02

In accordance with Section GTR placed at Part-C after commissioning and before handing over, the entire plant shall be subjected to System Trial Operations. The duration of Trial Operations of the complete equipment shall be fourteen (14) days with minimum twelve hours daily operation. For successful Trial Operation, the trial shall necessarily include steady operation of the plant at its rated flow path capacity for at least one hour duration per day on an average. PERFORMANCE REQUIREMENTS The Contractor shall guarantee that the equipment offered shall meet the ratings and performance requirements stipulated for various equipments covered in the specification.

1.01.03

1.01.04

1.01.05

GUARANTEES The Contractor shall furnish a declaration in the manner prescribed and included in the relevant Attachment of Section-VII for the following guaranteed parameters which shall attract levy of liquidated damages for shortfall in Performance. Capacity in T/Hr (equivalent to 100% of rated) of conveyor system including the intermediate equipments for each of the two parallel conveyor streams separately or any combination thereof to be tested in the following flow path operations. (i) Flow Path IA (Direct Stream): Apron feeder AF-1 taking feed of incoming coal from Wagon Tippler-WT-1 and discharging crushed coal into existing conveyor 3A/3B of Stage-I including all intermediate Conveyors and equipment. (ii) Flow Path IB (Direct Stream) : Apron feeder AF-2 taking feed of incoming coal from Wagon Tippler-WT-2 and discharging crushed coal into conveyor-21 of stage-II including all intermediate Conveyors and equipment. (iii) Any Combination of the above paths for the purpose of checking the control system. Further for the purpose of Guarantee tests Conveyor 21 along with all associated equipment shall also be considered.
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIB-01 PG TEST PROCEDURE PAGE 1 OF 43

(iv)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

GUARANTEE TEST PROCEDURE Major Equipment Capacity Guaranteed capacity in T/Hr of the following : Apron Feeders Crushers Vibrating Screen Feeders Wagon tippler with side arm charger Note : Guaranteed (rated ) capacities of above equipments are indicated in section IIIA-01.

1.01.06

1.01.07

Power Consumption Total power consumption for all the equipments including auxiliaries with single stream operation at its guaranteed flow path capacity except. Lighting Hoists Coal sampling unit Sump Pumps Elevators DS, DE, Ventilation, SW System, Potable water system

1.01.08

Performance Requirements to be Demonstrated Performance requirements of various individual equipments / systems as specified, including but not limited to certain minimum requirements as spelt out in the Guarantee Test procedure shall also be demonstrated during the Guarantee Tests to the full satisfaction of the Employer.

2.00.00

GUARANTEE TEST PROCEDURE In accordance with Section GTR placed at Part-C, on successful completion of System Trial Operation and commissioning, the plant shall be subjected to guarantee tests. Further, the guarantee tests shall be conducted as per the procedure specified in the following paragraphs.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 2 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE Pre-Requisites to the Guarantee Tests The prerequisites to be ensured by NTPC and the Contractor prior to start of the tests are placed at Appendix-I and Appendix-II respectively. After successful completion of trial operation and commissioning the plant shall be jointly inspected by NTPC and the Contractor & a joint protocol shall be signed that the plant is fit for guarantee tests. Testing for Guarantees Flow Path Capacity Tests (a.) For each of the Flow Paths, two conveyor streams shall be formed with suitable CRISS-CROSS Combinations of A or B Conveyors/ intermediate equipments. Composition of each stream shall be decided by the Engineer and shall be recorded as per Appendix-III. All above streams formed shall be independently tested for performance & guarantee. Further, the equipments/ conveyors (except common equipments) used for performance testing of one stream shall not be used for performance testing of the other stream. While operating the guaranteed capacity of the flow paths, non-spillage of coal and non-choking of chutes/ equipments shall be demonstrated as indication of smooth continuous flow through the conveyor system.

2.01.00 2.01.01

2.01.02

2.02.00 2.02.01

(b.)

(c.)

2.02.02

Major Equipment Capacity Tests (a.) Guaranteed capacity of all the major equipments as identified shall be established separately by operating only one equipment out of the two of a set at a time. Following equipments shall be considered: Equipment (1.) (2.) (3.) (3.) Vibrating Screen Feeders Crusher (after blanking the screen of VGS) Apron feeders Wagon Tippler with side arm charger Capacity Requirement

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 3 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE Power Consumption Measurement (a.) The guaranteed power consumption as total sum of all the equipments as specified shall be measured during capacity test of the identified Flow Paths for both the streams separately. The load of the following items shall not be considered during measurement of Power Consumption for guarantee: Lighting Hoists Sump Pump Coal Sampling Unit Elevator DS, DE, Ventilation, SW system, Potable water system (b.) Measurement Terminal(s) The guaranteed power consumption for the entire Flow Path(s) shall be taken during capacity test as sum of the power measurements at the following terminals. (1.) (2.) (3.) 3.3/6.6/11 kV CHP incoming terminals 415 V CHP MCC incoming terminals. Switchgear terminal of any load connected to Employers Switchgear.

2.02.03

Further the power consumption for the equipments being fed from CHP board/LT board but not to be considered for guaranteed power consumption shall be measured separately at their respective MCC/LT & HT switchgear input terminals and shall be subtracted from the total power consumption measured. However, if conditions permit, such equipments may not be operated during power measurement duration. (c.) Time Duration Power Consumption measurement shall be done only for 30 minutes after the conveyor flow rate stabilizes at the guaranteed capacity.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 4 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE (d.) Meters Ammeter/Voltmeter readings shall be noted from the meters mounted on the control desk / LT switchgear / HT switchgear or if necessary by means of clamp type meters. For power measurement two wattmeter method / one wattmeter method (2 or 3 elements) shall be used. Accurate clamp type digital 3 phase wattmeters can also be used. Power measurement shall be taken after stable condition is achieved. Energy meters shall be used for measurement of power by side arm chargers. Wattmeters shall have a min. accuracy class of 1% Energy meter shall be of min 2%. CTs & VTs shall have accuracy of 1%. All meter readings shall be recorded. No corrective allowance shall be allowed over the measured values. The details of wattmeters and energymeter alongwith their calibration certificate shall be furnished to NTPC before start of tests. These measuring instruments shall be calibrated from govt. approved test house. Calibration certificates of all instruments must not be more than 1 year prior to test date. Seals of the instruments shall be opened at site in the presence of Engineer-in- charge. Zero error shall be checked before conducting the PG Test.

2.02.04

GENERAL (a.) Test Duration (1.) Normal duration of the above capacity tests shall be four hours. However, minimum one (1) hour continuous & steady operation shall be required to establish the guaranteed capacities. In case of any minor interruption due to operation of electrical protection as well as stoppage due to safety reasons, the duration of test shall be extended by the time lost in such interruptions. In case of exceptionally longer interruptions calling for re-mobilization and repreparation of plant the implications shall have to be mutually discussed and agreed upon.

(2.)

(b.)

Weighing scales (1.) For measurement of flow capacity of a stream and individual equipments, weighing scales installed in the system shall be used.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 5 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE (2.) Readings for flow rate capacity test shall be taken at intervals of every 3 minutes. Belt weighers accuracy as demonstrated/ observed jointly before the guarantee testing may be considered for allowing correction factor over the recorded flow capacity reading.

(3.)

(c.)

The observations of guarantee test for various streams/ equipments shall be recorded in the formats at Appendix III to X and Performa 7 to 16.

2.03.00

Testing for Demonstration Requirements The specified performance parameters of various equipments/ system including but not limited to the following shall be demonstrated to the full satisfaction of the Employer.

2.03.01

Conveyors (a.) Conveyor Profile (1.) Check against lifting of Conveyor belts over concave curves at the time of start under empty belt condition. Check against wrapping/folding of belt over convex curves/transition zones. There should not be any roll back of coal pieces on moving or stopped conveyors There shall not be build up of coal in chutes , spillage of coal from skirt/conveyor/hoods while the belt is running. Smooth non-jerky running of conveyors with no spillage of coal and centric running of conveyors without vibrations of drives and galleries.

(2.)

(3.)

(4.)

(5.)

(b.)

Coasting Time Coasting down time of conveyors shall be measured and compared with design values. Check for spillage/blockage of coal from skirts/in chutes to be made. There shall not be build up of coal in chutes after stoppage of fully loaded conveyor so as to cause spillage of coal during next start.

(c.)

Belt Alignment To check against any sway during operation under different loadings and different conveyor criss-cross combinations.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 6 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE (d.) Idlers and self aligning idlers To check for satisfactory performance of idlers and self-aligning idlers (e.) Control/Sequential Operation (a) Performance checks for specified controls including sequential starting/ stopping of conveyors and other equipments as per approved control write-up. Satisfactory operation of PLC and control systems including absence of spurious trips/communication failures of PLC to be demonstrated. Demonstration for detection of operated pull cord/belt sway switch along with display in CRT of conveyor number and operated pull cord /belt sway number.

(b)

(c)

(f.)

Protection Switches Satisfactory operation of pull chord, belt sway, zero speed, chute blockage and other safety / protection switches.

(g.)

Load Start Demonstration of the ability of conveyor to start under full designed load.

(h.)

Simultaneous Operation Demonstration of simultaneous operation of both the streams under full load for 30 minutes in order to check healthiness of the system, electrical systems etc.

(i.)

Vibration Level in Conveyors Both velocity and amplitudes for all the conveyor drives and in each conveyor gallery under different conditions of conveyor operation as desired by site. Vibration limits of drive equipments shall be as per VDI 2056 / equivalent. Observations shall be recorded as per the format at Appendix-V. Vibration of conveyor galleries at trestles and pt. between trestles shall be measured and these values shall be within allowable limits. Vibrations of Crusher houses floors and transfer point floors shall also be measured and these shall be within allowable limits.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 7 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE (j.) GEAR BOXES Temperature rise not to exceed design values. No leakages No abnormal sound. Satisfactory performance of hold back devices in preventing running back of conveyor belts in case of conveyor being stopped in fully loaded (at design load) condition to be demonstrated. (k.) Fluid Coupling. No excessive rise of temperature. Satisfactory and quick operation of scoop in manual/remote modes with no oil leakages. (l.) Brakes Satisfactory and non jerky operation to avoid hold up of Coal in chutes. (m.) Skirt board and skirt sealing, inspection door, chute joints Perfect sealing with no spillage/no dust from sealing areas.

2.03.02

Metal Detector (a.) Tests for detection of specified smallest size pieces (25 mm sphere) of different metals including aluminium. Operation of liquid spray marker/ multiple markers. Demonstration of coast count, total count for multiple tramp metal pieces.

(b.) (c.) 2.03.03

In-Line Magnetic Separators/Suspended Magnets (a.) Demonstration of magnet capacity to separate out specified sizes and weights of magnetic pieces buried under (rated load) coal: MS cube of 20mm side Brake shoe of railway wagon (15 kg) MS plate of 250x250x10mm size

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 8 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE Shovel teeth and spikes (carbon steel) MS round bar of 50 kg with L/D ratio not exceeding 5 (b.) (c.) Collection of picked up pieces into tramp Iron chutes/ trolley Proper discharge of picked up metal pieces into tramp metal chute ( with no coal pieces going into it) Position adjustment

(d.) 2.03.04

Flap Gates (a.) Demonstration of remote, local and manual actuation of gates. Demonstration of successful changeover even while feeding coal. Check for stroke and operation of limit switches/ torque switches

(b.) 2.03.05

Dust Suppression System (a.) (b.) Measurement of head of pumps compressor. Pressure available at nozzle manifolds (on random basis) in running condition not to be less than of 0.5 kg / cm2 for water and 5.0 kg / cm2. Proper functioning of pressure regulating stations in case of fogging type dust suppression system (c.) Satisfactory spray atomization and dust suppression effectiveness of all the DS systems as per Appendix-VIII. Measurement of SPM before and after DS system operation as per Appendix - VIII. Complete coverage of yard by spray units in stockyard. Measurement of noise level and vibration (velocity and amplitude) at the bearing of motors and pumps.

(d.)

(e.) (f.)

2.03.06

Ventilation system (a.) Measurement of rated volumetric capacity of fans of atleast 2 nos. of each type and rating. Measurement of vibration (velocity and amplitude) at the bearing of motors and fans (wherever possible)
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIB-01 PG TEST PROCEDURE

(b.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 9 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE Package Air Conditioning (PAC) Unit (a.) Specified temperature and humidity of conditioned space under worst ambient conditions. Demonstration of rated capacity of PAC unit.

2.03.07

(b.) 2.03.08

Belt Weighers (a.) Demonstration of specified weighing accuracy of + 0.25% between 20% and 120% of rated capacity Satisfactory operation of flow rate indicator and totaliser etc.

(b.) 2.03.09

Vibrating Screening feeder (1.) (2.) Demonstration of variable capacity adjustment Observation of little tendency of choking/ build-up with coal having maximum moisture of 20% Little transmission of vibration to building structure, floor

(3.) 2.03.10

Coal Sampling Unit (1) (2) Demonstration of bias testing on random basis Demonstration of satisfactory of operation of CSU which shall necessary include ability to collect samples automatically and continuously for a minimum period of 7 days of conveyor operation without requiring manual intervention

2.03.11

Crushers Output coal size to be sieve analyzed and (-) 20 mm coal to be more than 98% for ring granulator type crusher. Vibration measurement (velocity and amplitude) is to be recorded at bearings as per appendix. Vibration is to be within allowable limits. No excessive rise of temperature of bearings. One crusher is to be tested for output and size after blocking VSF. Proper functioning of vibration monitoring system to be checked.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 10 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE Belt Scrappers Satisfactory operation of belt scrappers shall be demonstrated even with wet coal as specified. Scrapping efficiency of belt scrapper shall be minimum 95%.

2.03.12

2.03.13 2.03.13.01

Noise Levels Noise level measurement, for conformance to specified levels, to be done around the following equipments/ areas: (a) Conveyor Discharge Terminal (including discharge chute, gearbox, coupling & motor). Coal discharge chutes on intermediate floors in possible impact zones. Ventilation fans Water Supply & Dust Suppression Pumps. Coal crushers Vibrating Screening Feeders

(b) (c) (d) (e) (f) 2.03.13.02

Noise level measurement shall be done around the specified equipment location in the following manner. (a.) The measurement shall be carried out with a calibrated integrating sound level meter meeting the requirements of IEC-651 or BS-5969 or IS:9779. Sound pressure level shall be measured all around the equipment at a distance of 1m from the vertical projected plan of the equipment as a whole (this shall include coupling, gear box, motor etc.) at a height of 1.5 m from floor level. Microphone positions shall be at horizontal separations of not more than 1.5m around the equipment. The measurement shall be done with slow or impulse response, as the case may be on the A-weighting scale. The average of the A-weighted sound pressure level measurements expressed in decibels to a reference of 0.0002 micro bar shall not exceed the guaranteed value indicated in the specification. The tests shall be carried out with the equipments operating at near rated speed & load Correction for background noise will be considered Inline with IS:4758. Noise level measurement shall be recorded as per format at Appendix-VI.

(b.)

(c.)

(d.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 11 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE Elevators a) b) c) d) e) f) Check for average speed and load capacity Leveling accuracy Trouble free smooth operation Satisfactory operation of controls and limit switches Unmanned tests of safety devices like brakes etc. Testing as per manufacturers PG Test Procedure given in Annexure-I

2.03.14

2.03.15

Movable belt feeder a) b) Demonstration of remote, local and manual actuation. Check for travel, brake and operation of limit switches.

2.03.16

Wagon tippler a) b) Smooth operation of wagon tippler with out jerks Demonstration of guaranteed capacity of unloading of wagons in terms of load, no. of wagons and tippling rate and entries to be made as per format. Free flow of coal from the wagon tippler hopper even with wet coal having 20% moisture. Demonstration of tippling rate of 20 wagons/hr. Demonstration of side arm charger for auto operation of 58 wagon rake. Demonstration of DS spray system as per clause 2.03.05.

c)

d) e) (f)

Apron Feeders Satisfactory operation even with wet coal containing stones and moisture upto 20% Guaranteed capacity coal flowing capability Vibrations of drive within permissible level No spillage of coal

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 12 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

ANNEXURE -I Elevator Sl. No. NAME OF THE PROCEDURE TEST EXPECTED RESULTS REMARKS /RESULT OBTAINED

1.0

Trial Run

Test each times)

landing

(5

a) Push the UP, Cage should Results of Test STOP and DOWN respond buttons at every correctly to 1 2 3 4 5 landing each button

b) Try to operate the Hoist must not hoist with the UP start. and DOWN button leaving the landing door open (cage door closed) c) Close the landing -dodoor and also the cage door, keep the stop button pressed while trying to operate the Elevator with the "UP & DOWN buttons five times. d) At each landing floor, the level deviation should be within specified limits.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 13 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

ANNEXURE -I Sl. No. NAME OF THE PROCEDURE TEST Check for Operate the elevator with operation from the UP STOP & inside cage DOWN button five times EXPECTED RESULTS REMARKS /RESULT OBTAINED

2.0

Cage should Results of Test respond correctly to 1 2 3 4 5 each button

3.0

Check for a) Try to operate the interlocking elevator UP & DOWN leaving the cage door open (landing door closed). (All the doors are to be tried separately)

The elevator must not start when testing according to a,b,c and d.

b) Try to operate the -doelevator UP & DOWN leaving the trap door open (cage and landing door closed). c) Try to operate the -doelevator UP & DOWN keeping the emergency stop button pressed after the test. d) Check the other -dointerlocking equipment in the same way (each landing) e) Turn the switch Location / Operation in the electric box on the cage roof to Erection and test according to a), b) and c) from the cage roof. Reset the switch to Operation

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 14 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

ANNEXURE -I Sl. No. NAME OF THE PROCEDURE TEST Check for a) Start at the ground Automatic landing and operate System Stop from the push button Next Landing box in the Cage, Push the 0-button as soon as the elevator has started. b) Continue upwards and test all landings in the same way. c) Make the test according to a) & b) but now in the opposite direction Cage must stop at the next landing in the direction of travel. EXPECTED RESULTS Cage must stop at the next landing in the direction of travel. REMARKS /RESULT OBTAINED

4.0

NOTE : At the top and bottom landing, no signal is required from the the 0-button (STOP NEXT LANDING) to stop the elevator. The elevator stops automatically due to the top and bottom limit cams. 5.0 Check for travel Before start of test, speed check and record voltage and frequency of incoming power supply a) Start from ground landing and operate the UP button b) Start a Stop Watch when cage is in line with first landing

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 15 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

ANNEXURE-I Sl. No. NAME OF PROCEDURE THE TEST c) Stop the Stop Watch when cage is in line with second landing and note the timing. Press Emergency Stop button d) Release Emergency Stop button and press DOWN button. e) Start the Stop watch when cage is in line with second landing f) Stop the Stop Watch when cage is in line with first landing and note the timing. Continue to ground landing where cage will automatically stop. Calculate travel speed by the formula : EXPECTED RESULTS The rated travel speed should be checked at 415 V, 50 Hz and should be as specified REMARKS /RESULT OBTAINED

Speed = Distance (m) / Time (minutes) N.B. The test may be repeated for longer travel distances 6.0 Checking of a) Electro-magnetic Safety Devices brake and manual brake release operation during power failure. The Electromagnetic brake and Manual brake release shall function as per their design and the brake shall hold without creep at all levels.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 16 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE ANNEXURE-I

Sl. No.

NAME OF PROCEDURE THE TEST b) Over travel switch

EXPECTED RESULTS Cage must stop automatically at Ground and Top landings.

REMARKS /RESULT OBTAINED

c) Reverse phase relay Lift will not start in case of operation reversal of phase d) Alarm at the basement Should operate when button is pressed in cage e) Remote control for testing the safety devices as per Technical Specifications 7.0 Drop Test Make the test according Safety Device should stop to suppliers procedure cage in less than 7 m. of travel Note : Remember to reset the safety device after the test has been carried out. 8.0 Measurement of Power Current and power measurement by will be carried out during elevator movement upwards and downwards in loaded condition Measured current & power will be within the limits as specified in the Technical Specifications. Ensure that no person is present inside the cage during the test.

1. All tests to be conducted with full load Note : 2.Erection platform and erection crane to be removed before conducting tests. NTPC /Site Project Manager -------------------------Signature : Name : Designation : Contractor ----------------Signature : Name : Designation :

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 17 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-I GENERAL PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY NTPC 1. Availability of adequate and uninterrupted supply of coal. Specifications of coal as per N.I.T and as observed during the test shall be recorded as per attached format (Appendix-IA). 2. Sufficiently empty bunkers to facilitate continuous tripper dumping of coal during the test and sufficient space in coal stockyard. Uninterrupted power supply within specified parameters for the duration of the test. Belt protection switches, local stop push buttons, hooters, brakes/rail clamps in working order. Adequate and uninterrupted water supply. Plant communication system Proper lubrication and oil level of all equipments. Free rotation of idlers and pulleys. Cleanliness of plant and removal of coal spillage at the start and during Tests. Power supply voltage and frequency shall be as per technical specifications. Availability of dry coal during testing of DS system

3.

4.

5. 6. 7. 8. 9. 10. 11.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 18 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-IA COAL PARAMETERS Project Package Date : : :

As specified,

As observed during the test

1. 2. 3. 4.

Size HGI Moisture Shale and sand-stone content

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 19 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

PG TEST PROCEDURE APPENDIX IB JOINT DECLARATION BY NTPC AND VENDOR ON READINESS OF PLANT FOR PG TEST Project : VINDHYACHAL SUPER THERMAL POWER PROJECT Package: WAGON TIPPLER, CONVEYING AND CRUSHING PLANT PACKAGE Date :

The above system consisting of wagon tippler, conveyors and crushing plant was jointly inspected by NTPC and VENDOR on _________________. The present state of the plant is generally conducive to conducting the PG test. (Any observations to be enclosed as annexure) It has been jointly agreed that PG test of the said package shall be conducted with effect from date_______________.

NTPC

VENDOR

Sd/-

Sd/-

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 20 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-II PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY CONTRACTOR 1. 2. Deputation of team to site to associate with the Guarantee tests, Calibration of belt weigher scales and accuracy of same to be demonstrated to NTPC. Arrangement of wattmeters / energymeters calibrated and sealed from approved Govt. test house or NTPC site laboratory. Arrangement of any other instrument/ accessory for the test. Proper adjustment of skirt boards and belt cleaners prior to the start of tests. Arrangement of calibrated equipments for measurement of vibration & noise levels. Protection Relays of LT/HT switchgears and all motor feeders shall be checked. Belt protection switches, local push buttons, hooters, brakes/rail clamps to be in working order. Free rotation of idlers and pulleys. Protection relays of LT/HT switchgears and all motors/transformer feeders to be checked. Sufficient illumination.

3.

4. 5.

6.

7.

8. 9.

10.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 21 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE ANNEXURE IIA FORMAT FOR SUBMISSION OF GUARANTEE TEST PROCEDURE Clause No. as per Provision of Name and LOA/ Tech. Specs. LOA / Tech. Methodology of Specs. Test proposed by Vendor NTPC comments on the tests proposed by vendor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 22 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-III GUARANTEE TEST PROFORMA FLOW PATH CAPACITY TEST Project Package Date 1. : : : Composition of Stream i) ii) iii) 2. 3. 4. 5.
6.

Conveyor Nos. Dust suppression pumps, service water pumps, Ventilation fan drives. .......................... : : : : :

Location of Belt Weigher (s) Plant started (Time) Material started flowing over belt weigher (Time) Test period Completed (Time) Reading taken at three (3) minute intervals

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 23 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

Sl.No

Time

Flow Rate

Totaliser

Total plant run time Average Flow Rate

: :

NTPC

Contractor

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PAGE 24 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-IV GUARANTEE TEST PROFORMA POWER MEASUREMENT Project : Package Date 1. 2. 3. 4. 5. 6.


Sl. No.

: :

Equipment/Stream Composition Motor Description Sr. No. of meters used Date of Calibration of instrument and name of test house Multiplying factor (M.F.) of the wattmeter Wattmeter Readings (to be taken at 1 minute intervals)
Measurement Terminal Location Time Voltage Current (Volts) (amps) kw M.F. W1 Reading

: : : : : :
Total (W1+W2) MF kw Remarks

W2

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 25 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-IV 7. Sl. No. Energymeter Readings Equipment Time Duration Initial Final Energymeter Readings kwHr Initial Final Equipment Remark kw (R2R1)/(t2-t1)

*Reason and duration for system trip/stop may be recorded in remarks column.

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 26 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-V GUARANTEE TEST PROFORMA VIBRATION LEVEL MEASUREMENTS Project : Package Date Time : : :

Details of vibration Level Meter 1. 2. 3. Make Model & Sl.No. Date of calibration with name of Test House Sl.No Equipme Pick *Point Horizontal Micron/ mm/ sec. Vertical micron/ mm/sec. Axial Micron / mm/sec. Vibration level Amplitude/Velocity

Reading shall be taken at all the bearings of motor, gear box and driven equipment. In case of conveyor galleries, vibrations shall be measured at min. three locations, at midpoint of stringer between two short supports.

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 27 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX-VI GUARANTEE TEST PROFORMA NOISE LEVEL MEASUREMENT Project : Package Date : :

Details of Sound Level Meter 1. 2. 3. Make Model Date of calibration with name of Test House Sl.No Equipment with location Equipment load/capacity Measurement* point no. Sound level dBA. Remarks

NTPC

Contractor

* For each equipment location, a Projected Plan Diagram shall be made and the location of measurement points shall be identified.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX - VII WAGON TIPPLER

1. 2.

Nos of Wagon Tippled Time of placement of first wagon on wagon tippler platform Time of removal of last wagon from wagon tippler platform Total no. of wagons tippled Total time take (3-2) No. of tips/hr. = Total wagon tipped Total time taken = Sr.No.4 = Sr.No.5

: 58 :

3.

4. 5. 6.

: :

7. 8.

Over all performance Date of testing

: :

Satisfactory / Not satisfactory

For NTPC

For Vendor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 29 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE APPENDIX - VIII

DUST SUPPRESSION SYSTEM Fixing of acceptance criteria of ambient air quality Acceptance criteria of ambient air quality shall be considered with respect to respirable dust only. Respirable dust is defined as particles having particle size less than 10 microns meter (Not even equal to 10 microns meter). The particle size analysis of dust at any one of the area shall be carried out as a sample by placing the High Vokane. Sampler in the designated test point (1.5 to 3 M radius of application point) for a period d 8 hours without the system in operation under load. The sample thus collected will be subjected to the perwe size analysis by sieve Analysis method as a standard test laboratory. The quantity respirabte dust shall thus be determined from patbcie size Analyser. Percentage of quartz in respirable dust will be determined by X-ray diffaction. Acceptable Norms : i) If the respirable dust fraction contain less than 5% quartz. The permissible concentration of respirabie dust shall be less than 2 Mg/M3. In case, respirable dust has more than 5% quartz, the permissible concentration of respirable dust shall be computed as per following formula. Threshold limit value for farespirable coal dust in work environment (Mg/M3) 10 = iii) % Quartz in respect Dust +2

ii)

% Quartz shall be determined by X-ray diffraction.

TEST METHOD (Testing shall not be done during Monsoon) For determining the ambient respirable dust level average 4 hourly sample reading shall be taken with high volume sampler at each test point (1.5 to 3 Metre radius of application point) with chemjet system and material handling system in operation on load. The average of three such readings shall be taken for each test point to compute the respirable dust level. Respirable dust level will be determined by analysis of the sample using sieve analyzer.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 30 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX - IX SIDE ARM CHARGER

1.

Capacity

Haulage limit of -----MT. (--- Nos loaded wagons) Satisfactory / Not satisfactory

2.

It can/cannot pull ---Nos wagons

3. 4. 5.

If not, mention the reasons Time of test Date of test

: : :

For NTPC

For Vendor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 31 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

APPENDIX - X

WEIGH BRIDGE

A. B. Sr. No.

Wagon Tippler No Date of Test Date Type of Remarks wagons

: : Wagon measured Weigh bridge Gross Tare Wt. Wt. Weight mentioned

Net Wt.

on Wagon Tippler Net Wt. Tare Wt.

For NTPC

For Vendor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 32 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

PROFORMA 7 CONTROL AND SEQUENTIAL INTERLOCKS

1.0 2.0 3.0 4.0 5.0

Date and time of starting test Date and time of completion of test Path and streams being tested

: : :

Document No. of approved control write up : Observations - Control / sequential interlocks are checked: On no load and found Working Not working Satisfactorily satisfactorily

- If found not working satisfactorily, list the : ____________________________ Defects observed ____________________________ - Performance of PLC - Communication failures of PLC - Display of operated pullcord / belt Sway No on CRT 6.0 Workmanship of control-cum-mimic Panel is satisfactory There are spurious trippings Other tests (as given elsewhere in this Procedure and technical specifications) ____________________________ ____________________________ ____________________________

: Yes / No : Yes / No

7.0 8.0

NTPC

Contractor

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CLAUSE NO.

GUARANTEE TEST PROCEDURE

PROFORMA 8 CONDITION OF CHUTE & CHUTE CONNECTIONS

1.0 2.0 3.0 4.0 5.0

Location Date and time of starting of test Date and time of completion of test Path and stream being tested

: : : :

Observations on chutes ___________________________________________________________________ Sl.No. Transfer point Choking Dust leakage Remarks ___________________________________________________________________ i) Transfer chute from to. Transfer chute from . To Transfer chute from .. to .. : Yes / No

ii)

iii)

6.0

Inspection doors are provided at an Intervals of 3M and at convenient Locations with proper platforms and No interference with floors, structures etc. Inspection doors, chute flange joints Etc. are

: Perfectly sealed / Not properly & no leakages sealed

7.0

Other tests (as given elsewhere in this Procedure and technical specifications)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 34 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 9 MAGNETIC SEPARATOR

1.0 2.0 3.0 4.0 5.0 5.1 5.2

Location Type of magnetic separator Date and time of starting test Date and time of completion test Performance on full load Start/Stop (Whether Lifting)

: : : : : : Yes / No Remarks SM / ILMS

Is separation of Tramp iron pieces of requisite: Weight and size burried under coal effective Discharge of tramp iron is satisfactory (Applicable for ILMS) (All pieces need to be discharged into The tramp iron chute) ( No coal pieces Discharged in tramp iron chute) Slippage of belt over the pulley (Applicable for ILMS) Other observations (Bearing temperature,) Magnet body temperature Current drawn at the time of energizing Current drawn after 4 hours of energizing :

5.3

Yes / No

5.4

Normal / Abnormal

5.5

: _____________________ _____________________ _____________________ : : Amps Amps

5.6 5.7 5.8

Gauss value at the face of the magnet & at : The belt surface at the time of energizing & After four hours of energizing There is no sway of belt throughout The trial operation Other tests (as given elsewhere in this Procedure and technical specifications) : Yes / No

5.9

5.10

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 35 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 10 METAL DETECTOR

1.0 2.0 3.0 4.0 4.1 4.2

Location Date and time of starting of test Date and time of completion of test Performance Start / Stop Is metal (25mm spheres of different Metals including aluminium) detected / Identified properly Sounding of buzzer and tripping of belt On detection of metal is satisfactory? General observation (Search coil & hooter) Performance of coal counter/total counter

: : : Remarks : : Yes / No

4.3

Yes / No

4.4

4.5

Satisfactory / Not satisfactory Satisfactory / Not satisfactory

4.6 4.7

Performance of INK marker Other tests (as given elsewhere in this Procedure and technical specifications)

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 36 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 11 SUMP PUMP

1.0 2.0 3.0 4.0 4.1

Location Date and time of starting the test Date and time of completion of test Performance observation Start / Stop Whether pumping Required Vibration at motor bearing level Noise level at 1.0m from pump Is Functional Test Satisfactory (Whether pump is able To handle slurry) General (Performance satisfactory) Performance of auto level switch Other tests (as given elsewhere in this Procedure and technical specifications)

: : : Remarks : : : : : Yes / No

Yes / No Horizontal Vertical

4.2 4.3 4.4

4.5 4.6 4.7

: :

Yes / No Satisfactory / Not satisfactory

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 37 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

PROFORMA 12 RACK AND PINION GATE OPERATION

1.0 2.0 3.0 4.0 5.0 5.1 5.2

Designation Location Date and time of starting of test Date and time of completion of test Performance Start / Stop Remote, local, manual Observation on operation for no coal flow Remote, local, manual Observation on operation for full coal flow

: : : : Remarks : :

5.3

5.4

Coal leakage / spillage in the blocked path, : If any Provision for the operation of manually Provided with suitable safety switch General Observations a) Whether operation of gate is smooth b) Any other : : : Satisfactory / Not satisfactory Yes / No : Yes / No

5.5

5.6

5.7

Stroke and operation of limit switches, Torque switches Other tests (as given elsewhere in this Procedure and technical specifications)

5.8

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 38 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 13 VIBRATING SCREEN FEEDERs

1.0 2.0 3.0 4.0 4.1 4.2

Capacity of Grizzly feeder Date and time of starting the test Date and time of stopping the test Performance on full load Equipment start / stop Vibrations in microns a) b) c) At screen bearings At screen motor bearings At floor at various locations At 1.0m from screen

: : : Remarks : : : : : : ______________db Horizontal Vertical

4.3 4.4 4.5

Noise a) General observation of (a) screen and its drive unit : Out put size from screen a) b) +20 mm % age presenting undersize material (-20mm) -20 mm % age presenting oversize material (+20 mm) : : Yes / No ________________TPH

Choking of screen observed 4.6 4.7 Input feed rate of coal as per conveyor scale General observation (Material flow choking of chute, dust leakage

Note : Minimum three samples shall be taken with adequate time gap.

From feeder / crusher cage, Temperature of bearings, Motors, gear boxes, etc. current in accordance with Motor rating) 4.8 4.9 4.10 4.11 Whether vibrations are transmitted to To building structure Choking tendency, if any Loosening of screens Other tests (as given elsewhere in this Procedure and technical specifications) : : : Yes / No

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 39 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 14 FLAP GATE OPERATION

1.0 2.0 3.0 4.0 5.0 5.1 5.2

Designation Location Date and time of starting of test Date and time of completion of test Performance Start / Stop Remote, local, manual Observation on operation for no coal flow Remote, local, manual Observation on operation for full coal flow

: : : : Remarks : :

5.3

5.4

Coal leakage / spillage in the blocked path, : If any Provision for the operation of manually Provided with proper safety switch General Observations a) Whether operation of gate is smooth b) Any other : : : Satisfactory / Not satisfactory Yes / No : Yes / No

5.5

5.6

5.7

Stroke and operation of limit switches, Torque switches Other tests (as given elsewhere in this Procedure and technical specifications)

5.8

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 40 OF 43

CLAUSE NO.

GUARANTEE TEST PROCEDURE

PROFORMA 15 RING - GRANULATOR

1.0 2.0 3.0 4.0 4.1 4.2

Capacity of crusher Date and time of starting the test Date and time of stopping the test Performance on full load Equipment start / stop Vibrations in microns (microns,mm/sec) a) b) c) d) At crusher bearings At crusher motor bearings At fluid coupling bearing Crusher floor at various locations At 1.0m from crusher

: : : Remarks : : : : : : : ______________db Horizontal Vertical

4.3 4.5 4.5

Noise a) General observation of (a) crusher, and its drive unit : Out put size from crusher sieve analysis a) b) c) +20 mm -20 mm -1 mm : ________________TPH

4.6 4.7 4.8

Input feed rate of coal as per conveyor scale Operation of scoop tube Coupling along with actuator for crushers General observation (Material flow choking of chute, dust leakage :

Note : Minimum three samples shall be taken with adequate time gap.

From screen / crusher cage, Temperature of bearings, Motors, gear boxes, etc. current in accordance with Motor rating) 4.9 4.10 Temperature of bearings Other tests (as given elsewhere in this Procedure and technical specifications) :

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

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CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 16 BELT WEIGHER

1.0 2.0 3.0 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

Location Date and time of starting of test Date and time of completion of test Performance on full load, half load Counter (panel) Counter (remote) TPH indicator Percentage meter Chart recorder Reading with test chain Accuracy +/-0.25 % General deviations Other tests (as given elsewhere in this Procedure and technical specifications)

: : : : : : : : : : : : Remarks

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIB-01 PG TEST PROCEDURE

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CLAUSE NO.

GUARANTEE TEST PROCEDURE PROFORMA 17 PLANT STOPPAGE RECORD Remarks

1.0 2.0 3.0 4.0

Date and time of starting test Path and stream being tested Date and time of trip Designation of equipment responsible For plant stoppage Reason for equipment trip / stop Prior to completion of test Date and time of restarting the plant Plant stoppage shall be considered as Equipment / system fault Break down time for this plant stoppage (Item 6.0 Item 3.0) Date and time of stopping the system. Time period of operation of the System (Item 9.0 Item 2.0)

: : : :

5.0

6.0 7.0

: : Yes / No

8.0

Hrs

9.0

10.0

Cumulative time period of operation during : The test considering earlier time period operated

NTPC

Contractor

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

SUB-SECTION-IIB-01 PG TEST PROCEDURE

PAGE 43 OF 43

PART - A SUB-SECTION-IIC-01 SPARES

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-A

CLAUSE NO.

SPARES

SPARES 1.00.00 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 described in the following paras. 2.00.00 MANDATORY SPARES (a.) The list of mandatory spares considered essential by the Employer is indicated in section VI, part-F. The Bidder shall indicate the prices for each and every item (except for items not applicable to the Bidders design) in the Schedule of mandatory Spares whether or not he considers it necessary for the Employer to have such 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. However during execution if such spares are found to be applicable, the Contractor shall supply them without extra cost to the Employer. The Bidder shall furnish the population per unit of each item in the Bid Forms and Price Schedules. Whenever the quantity is mentioned in sets the Bidder has to give the item details and prices of each item. Whenever the quantity is indicated as a percentage, it shall mean percentage of total population of that item in the this Project, 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 total requirement of the item for a unit, module or the station or a 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 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. The Employer reserves the right to increase/decrease the quantity or delete any of the mandatory spares parts prior to award of contract. The prices of mandatory spares indicated by the Bidder in the Price Schedules shall be used for bid evaluation purposes.

(b.)

(c.)

(d.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIC-01 SPARES

PAGE 1 OF 4

CLAUSE NO.

SPARES (e.) All mandatory spares shall be delivered at site at least two months before scheduled date of initial operation of the first unit. However, spares shall not be dispatched before dispatch of corresponding main equipments. Wherever quantity is specified both as a percentage and a value, the Contractor has to supply the higher quantity until and unless specified otherwise.

(f.)

3.00.00

RECOMMENDED SPARES (a.) In addition to the spare parts mentioned above, the contractor shall also provide a list of recommended spares for 3 years 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 Section-VI, part-F and should be independent of the list of the mandatory spares. The Employer 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 of first unit. However, the spares shall not be dispatched before the dispatch of the main equipment. 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 3 months from the last date of providing such justification to the satisfaction of the Employer.

(b.)

4.00.00

START-UP & COMMISSIONING SPARES Start-up and commissioning spares are those spares which may be required during the start-up and commissioning of the equipment/system. All spares used till the plant is handed over to the Employer 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 Contractor.

5.00.00 5.01.00

COMMON REQUIREMENTS: The Contractor shall include in his scope of supply all the necessary Mandatory spares, start up and commissioning spares and recommended spares and indicates
TECHNICAL SPECIFICATIONS SECTION-VI PART-A SUB-SECTION-IIC-01 SPARES

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 2 OF 4

CLAUSE NO.

SPARES 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.

5.02.00

The Contractor shall indicate the service expectancy period for the spares parts (both mandatory and recommended) under normal operating conditions before replacement is necessary. 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. All the spares (both recommended and mandatory) shall be manufactured alongwith the main equipment components as a continuous operation as per same specification and quality plan. The contractor will provide Employer with cross-sectional drawings, catalogues, assembly drawings and other relevant documents so as to enable the Employer to identify and finalise order for recommended spares. Each spares 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 of identification. All cases, containers or other packages are to be opened for such examination as may be considered necessary by the Employer. The contractor will provide the Employer with all the addresses and particulars of his sub suppliers while placing the order on vendors for items/components/equipments covered under the contract and will further ensure with his vendors that the Employer, if so desires, will have the right to place order for spares directly on them on mutually agreed terms based on offers of such Contractors. 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. In addition to the recommended spares listed by the contractor, if the Employer further 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 for consideration by the Employer and placement of order for additional spares if the Employer so desires.

5.03.00

5.04.00

5.05.00

5.06.00

5.07.00

5.08.00

5.09.00

5.10.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIC-01 SPARES

PAGE 3 OF 4

CLAUSE NO.

SPARES The Contractor shall guarantee the long term availability of spares to the Employer 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 the Contract, he shall give the Employer atleast 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. Further, in case of discontinuance of manufacture of any spares by the Contractor and/or his sub contractors, Contractor will provide the Employer, two years in advance, with full manufacturing drawings, material specifications and technical information including information on alternative equivalent makes required by the Employer for the purpose of manufacture/procurement of such items. In case of equipment supplied with grease/lubricants from imported origin, the supplier shall clearly indicate the indigenous equivalent of the grease/lubricant and source of supply so as to enable the Employer to procure these items from indigenous sources.

5.11.00

5.12.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIC-01 SPARES

PAGE 4 OF 4

PART - B MECHANICAL

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PART - B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY 1.00.00 The specifications as brought out in various Sub-sections for mechanical equipment shall be applicable to the system of proposed coal handling plant and specifically to all mechanical including their operation & control philosophy. However, some specific parameters of the entire system as a whole and the major equipment are brought out as under. PARAMETERS (a) Conveyor System (37A/37B, 38A/38B, 39A/39B, AF-1, AF-2, and MBF-1, MBF-2) i. ii. iii. iv. (b) Rated Capacity (Guaranteed) Design capacity Belt width Maximum Belt speed : : : : 1400 TPH 1540 TPH Minimum 1400 mm 3.2 M/sec.

2.00.00 2.01.00

Existing / Extended Conveyor System (Conveyor-21) i. ii. iii. Rated Capacity (Guaranteed) Belt width Maximum Belt speed : : : 2000 TPH Minimum 1600 mm 3.2 M/sec.

2.01.01

Belting and Pulleys (a.) Belt ratings shall be selected in such a way that there are only three (3) ratings of belting. This however excludes belting of belt feeders. Belting shall be completely interchangeable among same rating of belt. Minimum number of plies for belting shall be four (4). Other details of belting shall be as specified else where in the specification. For Pulley, following minimum parameters shall be followed: (1.) (2.) (3.) Shell thickness End disc plate thickness : : 16 mm (Min.) 24 mm(Min.) 5 Minutes

(b)

(c)

Maximum allowable deflection of shaft at hubs :

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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

PAGE 1 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (4.) Diameter : (i) (ii) All drive pulleys All balance pulleys : : 800 dia (min) 630 dia (min)

Further approval from belt manufacturers shall be obtained by the contractor regarding the adequacy of the pulley diameters. d) Maximum type of pulleys permitted based on pulley diameter and shaft diameter shall be limited to five (5). These shall comprise of two (2) nos. drive pulleys and three (3) nos. for all balance pulleys exclusive of Pulleys for Belt Feeder & SS pulleys.

2.01.02

Coal Crushers & Vibrating Screen Feeders (a) (b) Nos. required Guaranteed (rated) capacity (considering 100% feed coal above (+)20 mm size) Input size (for sizing of crusher) : Two (2) each

: :

1400 MTPH (-) 250 mm (occasionally 1-2% 400 mm lump) Min 98% down to (-)20 mm

(c.)

(d) 2.01.03

Guaranteed size of output from Ring Granulator type crusher

Apron Feeder (a) (b) (c) Nos. required Guaranteed (rated) capacity Design capacity : : : Two (2) 1200 MTPH 1320 MTPH

2.01.04

Wagon Tippler (Rota side) (a) (b) Nos. required (i) (ii) Guaranteed (Rated) capacity Design capacity : : : Two (2) 20 tips/hr (min) 24 tips/hr (min)

2.01.05

Side Arm Charger (a) (b) Nos. required Guaranteed (rated) haulage capacity
TECHNICAL SPECIFICATIONS SECTION-VI PART-B

: :

Two (2) 58 wagons

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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

PAGE 2 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS Dust Control System The capacity of the dust control system specified hereinafter is for Contractors guidance only. Contractor shall provide adequately sized and fool proof dust control system, the performance of which should be guaranteed by the Contractor as required in the Technical specifications. The performance guarantee test procedure is to be submitted by the Contractor. However, the capacity of the offered system shall not be less than the specified values below. a) Wagon Tippler Dust Suppression System (Plain water type) (1) Capacity of each nozzle : 2.0 lpm (min.) at 4.5 Kg/cm2 (min) to make suitable fogging. 500mm Two (2) zones, One (1) no. on each side All

2.01.06

(2) (3)

Nozzles spacing No of zones

: :

(4)

No. of nozzles operating Simultaneously

b)

Dust Suppression System (Dry fog type) (1) Operation : Water & air sprayed by Fogging nozzle. At all coal discharge & receipt point on all transfer point & crusher house 0.5 Kg/cm2 for water (min.) 5.0 Kg/cm2 for air (min.)

(2)

Location of spray

(3)

Capacity & Pressure at inlet of spray lead

c)

Dust extraction system Type : Venturi scrubber type

2.01.07

Service Water System Service water connections are to be provided in conveyor galleries & tunnels at 50 meter interval and one (1) no. on each floor of Transfer Points, toilets and minimum two (2) nos. on each floor of crusher house. (a.) Flow at each valve : 5 cub.m/hr

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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

PAGE 3 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (b.) Minimum discharge Pressure at tap point No. of valves operated simultaneously

: :

2 kg/sq.cm 6 nos.

(c)

2.01.08 2.01.09

Potable Water System Ventilation System A Mechanical Ventilation System i. Underground Areas :

: As specified elsewhere in the spec.

Minimum 15 supply air changes and minimum 7 exhaust air changes per hour. Minimum 10 supply air changes per hour. Minimum 15 supply air changes per hour Adequate number of air changes to Maintain in uniform temp. & humidity as specified elsewhere.

ii. B. C.

Other Areas

Pressurized Ventilation System: Air Conditioning System :

2.01.10

Chutes Minimum clear cross section of chute : Minimum clear cross section of : discharge chute for stone picking 1000 mm x 1200 mm (inside both ways). 750mm X 1000mm (inside both ways)

2.01.11

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, crushers, drive units, in line magnetic separators, sampling units, sump pumps, various DS/service water/potable water pumps, gravity take up units, apron feeders, suspended magnet, removal of equipment from tunnels & underground building lifting of belt drum etc.

2.01.12

All other equipment under the scope shall be suitable to the system capacities parameters as specified above. OPERATION AND CONTROLS This section is intended to cover control/instrumentation and operational philosophy as specified hereinafter complete in all respects, required for complete coal handling plant.
SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

3.00.00 3.01.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 4 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS General Requirements The instruments and controls to be furnished and erected under this specification are as required for safe and satisfactory operation of the Coal Handling System, as outlined under mechanical section and as specified elsewhere in the specification. For the equipment and materials procured by the Contractor from his sub-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 sub vendors and supply instrumentation and control to suit the actual Wagon Tippler, Conveying and Crushing Plant equipment.

3.02.00

3.02.01

Standards / Codes All construction, installation, workmanship, design & equipment shall conform to acts, rules & regulations of the jurisdiction within which the project is to be located, and to the current edition of the following or equivalent standards or codes, in so far as they apply : American Iron & Steel Institute (AISI) American Society for Mech. Engineers (ASME) American Society for Testing & Materials (ASTM) American Wire Gauge (AWG) Institute of Electrical & Electronic Engrs. (IEEE) Instrument society of America (ISA) National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA) United States of America standards (USAS) Bureau of Indian Standards (BIS) Conveyor Equipment Manufacturers Association (CEMA)

3.02.02 3.03.00 3.03.01

This Sub-section shall be read in conjunction with Electrical Sub-sections. General Construction and Design General Construction Control desks/panels and annunciation system shall be as per the requirement of electrical Section. Annunciations, indications, electrical meters and instrumentation shall be provided as specified.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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

PAGE 5 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS Design The Contractor shall provide a comprehensive control indication and annunciation scheme. Contractor shall furnish block diagram and write-up on the scheme proposed. The final scheme will be approved by the Employer. In general, interlocking shall be achieved through feed-back signals from field equipment. 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 face of LVS/Control-Panel/ TFT itself. 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 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 employer.

3.03.02

4.00.00

OPERATION AND CONTROL PHILOSOPHY The coal handling system shall be controlled from the following control points.

4.01.00

Coal Handling Plant Main Control Room Overall, operation of the following equipment of Wagon Tippler, Crushing and Conveying Plant shall be controlled from the main control room. (a.) Conveyors, feeders, flap gates, R & P gates, crushers, hydraulic scoop couplings. Complete Dust Suppression system, service water system, cooling water system & potable water system. Ventilation system (group/individual control as required). In line Magnetic separators and Suspended Magnet (ON/OFF control with indication). Metal Detectors (ON/OFF control with indication). Coal Sampling Units. Belt weigher (ON/OFF control with indication) Apron feeders & dribble conveyor (indication only).

(b.)

(c.) (d.)

(e.) (f.) (g.) (h)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 6 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS Local Control Panels Local control stations for following equipments shall be provided (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Belt Weighers Metal detectors Electric hoist - wall mounted control box with pendent push button controls. In line magnetic separators Suspended Magnet Sump Pump Coal Sampling Units Dust suppression system for wagon unloading at wagon tippler. Dust Extraction System Hydraulic scoop coupling.

4.02.00

All the above local control panels shall be accessible and located near their respective equipment and shall be complete with all the required controls, interlocks, annunciations etc. However, for items (g.) to (k) controls shall be through main PLC & MCC as applicable. Further, necessary controls, indications and annunciations for all the above equipment shall also be provided at main Control Room as described under relevant clause. 4.03.00 Wagon Tippler control Room The entire control & operation of wagon tipplers, apron feeders alongwith dribble conveyors and side arm chargers shall be from the wagon tippler control room. 4.04.00 In addition to the remote control of various equipment, local stop push button stations shall be provided for all equipment. System Operation Operation philosophy of the plant, in general, shall be as elaborated below: (a.) Coal flow path selection shall be done from CRT/Keyboard to select any one of the following conveying paths.

4.05.00 4.05.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 7 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (1) (2) (3) (b) Wagon Tippler to Stage I conveyors (con. 3A/3B) Wagon Tippler to Stage II conveyors (con. 21) Combination of above

The coal handling system operator will select any one of the above paths from OWS located on the main control desk. The flow stream path is then selected by positioning different flap gates/ movable discharge pulley at desired positions by means of keyboard available at the central control desk. Once the system is in the operation, the gates/ movable discharge pulley can not be moved from their positions and path. Flap gates which do not come in the stream in which coal flow is taking place, can be operated at any time. However, for the flap gates in bunker area conveyors, it shall be possible to change flap gate position while the conveyor is in operation and feeding coal using interlock bypass facility, provided that sequential permissive are available. The Control system will be designed for Auto & Manual operation of the conveyors in the selected path. Auto/Manual Selection shall be done from keyboard. 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 is activated, all conveyors will also stop 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 keyboard. The operator will also stop the conveyor system, by pressing "System stop" or individual Stop push buttons/command from keyboard in the reverse sequence.

(c)

(d)

During Sequence Start in both Auto and Manual modes, first the required number of hooters (3 phase induction motor type) will be energized simultaneously for a preset time of 1 minute or so (adjustable at site) as per the program. After the preset time, the hooters will stop and a preset time of two minutes (adjustable at site) as per program will be allowed for the movement of the personnel and for the permissive of the conveyor system operation. This condition will be indicated on the panel by glowing of lamp Coal Handling Sequence Start. The starting permissive will be available for a period of 5 minutes (Pre-programmed and adjustable in the field). In the event the last conveyor / equipment is not started within this preset time of 5 minutes, the start command for equipment not started will be withdrawn. The system cannot be started again unless the Sequence Start push button is again pressed and the hooters sound again, as described before. Those conveyors and equipment, which have already started, will continue to run.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 8 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (e) The status indication in the graphic display against all conveyors and equipment in the selected path/stream will start slow flickering. However, all status indications against all flap gates / movable discharge pulley in the selected path will glow steadily. Therefore, from the selected flow stream path of the flap gates / movable discharge pulley, the operator will come to know the conveyors and equipment to be started for the selected path/stream. After a conveyor/equipment is started, the status indications against that conveyor / equipment will change to steady glow indicating that it is running. Graphic display status indicators associated motor/equipment shall flicker fast in case of fault / trip. with a particular

(f)

(g)

In addition, emergency stop push button on the control desk for immediate shut down of complete plant shall be provided. Lamp test facility will be provided for the annunciation and mimic lamps.

(h) 4.06.00

Conveyor System (a) 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 track hopper or Wagon tippler. Provision shall be made for the same by the Contractor in control desk. Each conveyor shall be protected against damage to the edge of the belt due to excessive sideways movement by providing an 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. In case of speed of belt goes below 85% of rated speed, it shall trip the conveyor. All the conveyors shall be protected from reverse running due to power failure by providing mechanical or electrical locking system. The starting sequence of the conveyors shall follow a direction opposite to that of flow of material i.e. : (1.) In case of direct conveying of coal to Stage-I or II conveyors, start from Stage-I or II conveyor and end up with reclaim conveyors below Wagon Tippler The starting of apron feeders and wagon tipplers shall be interlocked with operation of the reclaim conveyors below wagon tippler hopper

(b)

(c)

(d)

(2.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 9 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (e) 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. Stop/tripping of any equipment from running condition shall trip all preceding equipment in the system, except crushers but shall not effect succeeding ones which shall continue to operate. Adequate number of pull-cord switches shall be provided at suitable intervals along the length of each belt conveyor, which shall enable the respective conveyor to be stopped immediately. Each pull chord switch shall be identified by a specific number on HMI in the main control room. Each belt sway switch shall also be identified by a specific number on HMI in control room. Means shall be provided to pre-warn personnel working nearby when starting any conveyor, Wagon Tippler. Interlocking of various conveyors shall be achieved with Flap Gate, discharge pulleys, Rack & Pinion gate, limit switches and zero speed switches. Motors shall start only when the brake/rail clamp if-provided, is in not applied condition. This signal shall be obtained from limit switch provided for that purpose. Ring granulators shall be provided with speed and vibration monitoring instruments. Ring granulators shall trip in case speed/ vibration is going beyond tolerable limits of design. Temperature sensing devices shall be installed on all bearings of each of the ring granulator to trip the ring granulator in case of temperature goes beyond limit. Audio-visual annunciation shall be provided in main control room and locally also. 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. This is to prevent jamming of gate. Where ever scoop type coupling provided for HT motors, the coasting time of respective conveyor, thrustor brake, actuator selection and the chute size shall be so selected such that there is no spillage of coal from any down stream conveyors during next start. Wherever the conveyor/belt feeder is provided with the movable discharge pulleys in place of flap gates, the starting of the conveyor/belt feeder will be interlocked with the position of the movable discharge pulley.

(f)

(g)

(h)

(i)

(j)

(k)

(l)

(m)

(n)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 10 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS Interlocking (a.) The following conveyors / equipment will come under interlock scheme :(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (b.) All conveyors All flap gates All movable belt feeders/pulleys Rack & Pinion Gates Metal detectors Magnetic Separators Crushers Belt scale Suspended Magnet Wagon tipplers Apron feeders & dribble Conveyors

4.07.00

The following equipment will not come under interlock of the conveyor scheme. (1.) (2.) All dust suppression systems & service water system. Ventilation systems

(c.)

All conveyors and equipment will have local push button stations each consisting of : (1.) (2.) Pos - I, Pos - II & stop button for flap gate and R & P gate Emergency stop push button (Red) for other equipment

(d.) (e.)

Belt scale shall be started when relevant conveyors are started. The dust suppression systems will be energized as soon as the conveyors are energized. Coal handling plant shall be tripped in case of detection of fire.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

(f.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 11 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (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 is indicative only and the Contractor shall develop a comprehensive interlocking scheme.

Conveyors (a) (b) (c) Pull - Chord switch - not operated Belt sway switch - not operated Under speed switch - closed at 90% speed of the conveyor within designed accelerating time. Motor protection - not tripped Local stop PB reset Chute Block switch - not operated. Brakes for conveyor not operated. Trip circuits healthy. Temp. of fluid coupling oil - not high

(d) (e) (f) (g) (h) (i)

Magnetic Separators / Metal Detectors / Suspended Magnets (a) (b) (c) (d) O/L / fault relay - not tripped. Stop PB (Local & Remote) reset. Metal detector reset Oil temperature - not high

Flap Gates/ R & P Gates: (a) End of travel limit switches - reset.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 12 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (b) (c) Torque limit switches - reset. Local stop - reset.

Ring Granulator (a) (b) (c) (d) (e) Zero speed - not operated Temp. of fluid coupling oil - not high. Local stop push button reset. Temperature of bearings not high. Cooling water flow switch reset

Wagon tippler (a) (b) (c) (d) (e) Motor O/L not tripped Local E-Shop PB-reset Shop PB in main CHP Control Room reset. All limit switches - reset All limit Switches not tripped.

Apron feeder (a) (b) (c) 4.07.01 Motor O/L not tripped. Local stop PB rest Dribble Conveyor not tripped.

The lists of indications and audio-visual annunciation given in subsequent clauses are indicative only and the same shall be finalised during detail engineering. Status indications in Large Video Screen Following individual status indications shall be provided in LVS with individual ON/OFF/TRIP indications on CRT. (a.) Conveyor 'ON'

4.07.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 13 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (b.) Flap Gate/Rack and Pinion. (c.) Belt scale flow rate indication 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.) Crusher ON (h.) MD/ ILMS/ SM/ CSU ON (i.) (j.) (k.) (l.) DS/ SW/PW/CW/DE/ Vent ON (System wise) Unit wise MW indication, total coalflow & Bunker level. Wagon Tippler ON Apron feeder - ON

Further Mimic lamps for HT and LT SLDs shall be provided on the control desk. 4.08.00 Annunciation System: DDCMIS/Control desk shall be provided with adequate number of facia type annunciation windows operating through DDCMIS for the following audio-visual fault annunciation purposes. Wherever group annunciation is provided, alarm status of individual equipment shall be provided on OWS. (a) (b) (c) (d) 3.3 kV Breaker Trip (Group wise for each board) 415 V MCC Breaker Trip (MCC wise) Bus under voltage for each LT MCC & HT switchgear buses. Following group wise annunciation shall be provided for transformers : (1.) Buchholz alarm (2.) Winding/oil temperature high alarm (3.) Oil level low alarm
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

PAGE 14 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (4.) Buchholz trip (5.) Winding/oil temperature high trip (e) (f) (g) (h) (i) (j) (k) (l) A.C Control Supply failure. D.C. Control Supply failure. Annunciation supply failure. Both CPU fail Stand by CPU in service H.T. motor overload alarm (individual) HT motor bearing/ winding temp. high alarm (group) and trip (group) HT motor trip on electrical fault (Group)

(m) LT motor overload tripped (Group). (n) (o) (p) (q) (r) (s) (t) (u) Crusher vibration monitor alarm (Group). Belt sway switch operated (Group) Pull cord switch operated (Group) Zero speed switch operated. (Group) Chute plugged (Group) Wagon rake arrived. Magnetic separator fault and cleaning belt trip. (i) (ii) (v) (w) Metal Detector fault (Group) Metal detected / MD not reset (Group)

Belt Scale fault (Group) Sampling system faults and trips (Group)

(ab) Dust suppression/service water / dust extraction system faults and trips (system wise)
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

PAGE 15 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (ac) Water level low in tanks (group) (ad) Oil temperature of fluid coupling high (ae) Crusher low speed & crusher bearing temperature high. (af) (ag) (ah) Wagon tippler tripped (group) Apron feeder tripped 20% spare window

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 start 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 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 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 / equipment will start slow blinking while the faulty conveyor / equipment will be fast blinking. Start command shall not be initiated unless reset button in pressed after clearance of fault. The sequence of operation of the annunciation system shall be as follows :Condition Normal : Ann. Window Status indication Buzzer : : : Status Off. Steady glow Off.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 16 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS

Fault

Ann. Window Status indication Buzzer

: : : :

Blinking. Fast blinking Sounding. Steady glow.

Press Accept. PB.

Ann. Window

Status indication Buzzer Press Reset PB (When fault is cleared): Ann. Window

: : :

Fast blinking Off. Off.

Status indication

i)

Steady blinking selected path)

(if

on

ii) Buzzer. 4.09.00 Dust Suppression System (a.) Conveyors / Equipment : Off.

Off (if not on selected path)

(1.) It shall be possible to operate the dry fog system on to coal stream only when corresponding conveyors/equipment are running with material at spray application points. (2.) If a running pump trips stand-by pump shall start automatically. 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 pressure & no flow by pressure switch. (6.) Motorized inlet valve to Dust Suppression tanks shall close in case of High-High level & open in case of low level.
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 17 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (7.) Pumps shall be started manually or from PLC. If any of the pump/pumps trips, stand-by pump/pumps shall start automatically. It shall be possible to select any of the pumps as auto stand - by. (8.) Following annunciations shall be provided at local control panel. (i) Motor electrical protection operated (Group) (ii) Discharge water pressure low (Group) (iii) Water level low in tank (Individual) (9.) 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. (b.) Wagon unloading (Wagon Tippler Hopper) (1.) System shall be operated from local control panel. However, the controls shall be through PLC. (2.) Dust suppression system shall be provided to cover the Wagon Tippler Hopper in maximum one sections. Push button for section shall be located on side of wagon tippler hopper at convenient location. (3.) Pumps shall be started manually or from PLC If any of the pump/pumps trips, stand-by pump/pumps shall start automatically. It shall be possible to select any of the pumps as auto stand - by. (4.) Pumps shall trip in case of low level of water in tank. (5.) Following annunciations shall be provided at local control panel. (j) 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

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 18 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (ii) Discharge pressure healthy (iii) Water level high in tank. (c) Following individual inputs shall be provided to PLC system from all the above dust suppression systems for alarms/indications. (i.) (ii.) (iii.) (iv.) Motor ON/OFF/TRIP Water level low in tank Water level high in tank Discharge pressure low

4.10.00

Metal detectors (a) It shall be possible to start the conveyors only after energizing the metal detector and Metal detector reset condition. Once the metal is detected, the corresponding conveyor shall trip. It shall be possible to restart the conveyors, after local resetting of metal detector and putting back the marker bag in position. Metal detector ON/OFF push buttons shall be provided in main control room also. (b) In case of tripping of conveyor system, metal-detector shall get de-energized after a time lag. Following individual indications shall be provided on local control panel. (1) (2) (3) (4) Metal detector ON Metal detected Metal detector 'reset'. Metal detector faulty.

(c)

4.11.00

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. Any of the pumps can be selected as auto-standby.

(b)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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

PAGE 19 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS (c) If the sump level continues to be high even after the first pump is under operation second pump shall start automatically. The following indications for sump pumps shall be provided on local Control Panel. (1.) Water level high (2.) Motor ON/OFF/TRIP.

(d)

4.12.00

Coal Sampling system (a) Coal Sampling Unit shall be controlled through main coal handling plant PLC. Controls and interlocks for proper material flow shall be provided similar to conveyor system. Mimic shall be provided in the Operator Work Station (OWS) at main CHP control room. Only one start/stop push button along with selector switches for various modes of operation of coal sampling system shall be provided for automatic operation of complete coal sampling system. This control facility shall be provided at main CHP control desk as well as locally. In any case, local push button stations shall be provided for all individual equipment of coal sampling system near the equipment. All necessary automatic controls shall be provided for meeting the requirements of ASTM-D-2234. Following indications shall be provided on local control panel (1.) System ON/OFF/TRIP (2.) Primary cutter stuck up between parking positions. (e) In case of primary cutter getting stuck between parking positions, preceding conveyor shall trip and annunciation shall appear at Main CHP Control room. There shall be protection in the primary coal sampler to trip the conveyor belt in case primary sampler falls on running conveyor due to coupling failure etc. Individual motor ON/OFF/TRIP indications shall be provided at main CHP control room.

(b)

(c)

(d)

(f)

4.15.00

Flap Gates/ R&P Gates All Flap Gates/ R&P Gates shall be motorised with remote controlled from the main control desk. Their position shall be indicated on the mimic of main control room.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 20 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS Belt Weighers Each belt scale shall give output to PLC for display of flow rate indicator and totalizer on TFT and print out at main CHP control room. 4 Nos. rate flow rate indicators, one for each paddle feeder shall also be furnished to display the instantaneous TPH on respective paddle feeder using the output of belt scale on Conveyors. Each belt scale shall also have rate flow indicator and totaliser mounted near the unit.

4.16.00

4.17.00

Magnetic separator / Suspended Magnet It shall be possible to start the conveyor only after energising the magnet of ILMS or SM. Further, if conveyor system trips magnetic separators shall get de-energised after a time lag and suspended magnet will remain energised and can be deenergised locally. Also if drive motor of cleated belt of ILMS trips, magnetic separator shall not get de-energised, but conveyor system shall trip and audio-visual annunciation shall appear at main CHP control room. Following individual indications shall be provided on local control panel (a.) Magnetic separator ON. (b.) Incoming supply ON (c.) Under current relay operated

(d.) Cleated belt motor ON/OFF/TRIP (e.) Oil temperature high 4.18.00 Service water, Cooling Water Dust Extraction and potable water pumps (a) (b) (c) These pumps shall be started from main CHP control room Pump shall trip in case of low water level in tank. Following individual inputs shall also be provided to PLC system for alarms/indications : (1.) Motor ON/OFF/TRIP (2.) Discharge water pressure low (3.) Water level low in tank (4.) Water level high in tank

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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

PAGE 21 OF 22

CLAUSE NO.

TECHNICAL REQUIREMENTS Wagon Tippler Wagon tippler shall be controlled from the local control panel suitably placed. Requirement of operation as described elsewhere in the specifications shall be complied with. Following indications shall also be provided on the local control panel: (a) (b) (c) (d) (e) Motor On/OFF Motor O/L protection operated Brakes applied (if provided) Hydraulic power Pack indications as applicable. Dribble Conveyor

4.19.00

Main Hydraulic pressure of champing drive system to be reduced to minimum through its control circuit during each tripping of main drive motor.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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

PAGE 22 OF 22

PART - B SUB-SECTION-IIIA-02 WAGON TIPPLER

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

WAGON TIPPLER 1.00.00 1.00.01 GENERAL (a) Rotaside wagon tippler shall be furnished complete with all structural members, tippler platform, tipping mechanism, tippler drive motors, brakes, couplings, shafting and all automatic controls for positioning, tipping and discharging the entire contents of the wagons into the hopper.

1.01.00 1.01.01

Wagon Unloading System The rake comprising of specified maximum 58 number of wagons shall be pushed into the reach of in-haul equipment by a locomotive. Further placing of wagons over tippler platforms and carrying away the empty wagons shall be accomplished with the help of a side arm charger under scope of bidder. Wagon tipplers shall be suitable to handle any type of wagons being used by Indian Railways as on date for transportation of coal as per IS-10095 (Latest edition) an shall conform to all stipulations with regard to suitability for handling wagons having width, height and length over coupler faces as indicated by RDSO/railway authorities at the time of approval of wagon tippler drawings. The rake comprising of specified maximum 58 numbers of wagons shall be pushed into the reach of in-haul equipment by a locomotive. Further placing of wagons over tippler platforms and carrying away the empty wagons shall be accomplished with the help of a side arm charger whose travel length shall suit the requirement of wagon tippler hopper dimensions approved by RDSO/railway authorities. 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. 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. Bidder shall take case of the observations of RDSO/Railway authorities in their designed & drawings for wagon tippler and its accessories. The top opening of wagon tippler hopper shall be suitable for receiving coal from wagons for which the wagon tippler drawing shall be approved by RDSO/railway authorities. The bidder shall obtain all statutory approvals from the relevant RDSO/Railway authorities, before the wagon tippler complex is put into operation. Any statutory payment charges, to be made to the concerned authorities shall be to Bidders
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-02 WAGON TIPPLER PAGE 1 OF 7

1.01.02

1.01.03

1.01.04

1.01.05

1.01.06

1.01.07

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS account. It is the responsibility of the Contractor to carry out any modifications as required by the RDSO/Railway authorities, at no extra cost to the Owner.

1.02.00 1.02.01

Wagon Tippler Hopper The wagon tippler hopper shall be of RCC construction and adequately sized to accommodate the coal load for atleast three (3) nos. 8 wheeled wagons of RDSO design used by Indian 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 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 from the hopper. Steel gratings of mesh size 350 mm x 350 mm over wagon tippler hopper shall be provided. The hopper and gratings shall be designed for movement of font end loader/bulldozer over them. Bull-dozer weight shall be considered as about 35T. 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 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 Employer shall be final and binding.

1.02.02

2.00.00

3.00.00 3.01.00

DESIGN REQUIREMENT The wagon tippler shall be rotaside type suitable to unload a coal wagon by lifting and rotating it sideways. The angle of tip shall be at least 150 giving 60 angle to the side of the wagon for emptying the coal contents into the hopper below. Wagon tippler design should take care of locomotive movement (WDG3A) over tippler table at creep speed. 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. The tippler shall be suitable for continuous operation, 24 hours a day, round the clock. Although the tippling rate shall be 20 Tips per hour all drive components, by

3.02.00

3.03.00

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SUB-SECTION-IIIA-02 WAGON TIPPLER

PAGE 2 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS hydraulic, electrical structures shall be designed for 24 tips per hour continuous operation.

3.04.00

The wagon tippler structure shall be designed to conform to the requirements of Indian Railways Research, Design and Standards Organisation, (RDSO), Lucknow 226011 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. The wagon tippler shall be suitably counter balanced at each stage of operation so as to require minimum driving power. Wagon Tippler weighing System 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 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 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 no., time, date etc. the weighbridge shall be chosen to accommodate 8 wheeler wagons of RDSO design used by Indian Railways to move coal. The weighbridge shall be supported on minimum 4 nos. compression type load cells mounted on free motion structural unit assembly. The load cells shall be suitable for dusty environmental conditions.

3.05.00

3.06.00 3.06.01

4.00.00 4.01.00 4.01.01

CONSTRUCTION REQUIREMENT Cradle The cradle shall consist of a pair of heavy welded steel plate sections reinforced with stiffeners and connected by side bearer beams pivotally attached, each section being fitted with a massive trunion shaft carried in bronze bushed cast steel bearings/antifriction type spherical roller bearing on each side, bolted to steel pedestal carried on concrete pedestals. Circumferential driving rack shall be rigidly 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

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-02 WAGON TIPPLER

PAGE 3 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS failure of one of the drive pinions and / or gear racks shall be provided and the same shall be clearly indicated in the bid.

4.02.00 4.02.01

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. Feeders and Clamps 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. Spill Plate Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting material into the tippler hopper. Driving Gear 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 motors using gear boxes or fully hydraulic drive (without gear box) as per manufacturers proven design, as applicable. Suitable oil coolers shall be provided for hydraulic power pack. Suitable dust protective cover shall be provided. Brake 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. Limit Switches Limit switches of suitable type which can be readily adjusted to give the desired tippling angle shall be provided. An emergency overtip limit switch operated by a striker on the tippler trunnion shaft shall be furnished. Ballast Ballast necessary for counter weight and balancing the tippler shall be provided as per the requirement.

4.03.00 4.03.01

4.04.00 4.04.01

4.05.00 4.05.01

4.06.00 4.06.01

4.07.00 4.07.01

4.08.00 4.08.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-02 WAGON TIPPLER

PAGE 4 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS Lubrication All bearings shall be properly lubricated. Grease nipples and reservoirs shall be furnished where necessary. Guards All gears inside machinery pits and other moving parts shall be securely guarded. 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.

4.09.00 4.09.01

4.10.00 4.10.01 4.10.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-02 WAGON TIPPLER

PAGE 5 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET 1.0.0 1.1.0 GENERAL Wagon Type : Standard broad gauge, 8 wheeler wagons of RDSO design used by Indian Railways to move coal As per IR norms. 1676 mm. Load cell type Continuous 24 hrs.

1.2.0 1.3.0 1.4.0 1.5.0 2.0.0 2.1.0 2.1.1 2.1.2

Moving Profile Rail Gauge Weigh bridge Duty DESIGN & CONSTRUCTION Wagon Tippler Hopper Construction Size

: : : :

: :

RCC Construction. To accommodate atleast (three) 3 nos. 8 wheeled wagons (min.180 Te.) One (1) 37

2.1.3 2.1.4

No. of openings Angle of repose of coal for wagon tippler hopper sizing Lining Steel Grating (i) Mesh size (ii) Grating Section

: :

2.1.5 2.1.6

50 mm thick guniting.

: :

350 mm x 350 mm 200 mm x 30 mm thick flats.

2.2.0 2.2.1 2.2.2 2.2.3 2.2.4

Wagon Tippler Type Tipping angle Duty Requirement Counter balancing : : : : Rotaside type Atleast 150 Continuous operation Suitable to keep power requirement at minimum.

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SUB-SECTION-IIIA-02 WAGON TIPPLER

PAGE 6 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.2.5 2.2.6

Cradle Driving Gear (i) Racks

Heavy welded steel plate construction trunion mounted.

Cast steel rack sections bolted to end sectors. Multiple pinions meshing with rack. Rolled steel joints with steel rails mounted on it. Hydraulic motors integral with Gear Box or direct hydraulic drive. Electro hydraulic thruster operated. Hydraulically operated Self aligning type made of resilient material.

(ii) Pinion 2.2.7 Rail Table

: :

2.2.8

Drive

2.2.9 2.2.10 2.2.11

Brake Clamping Top & side stops

: : :

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SUB-SECTION-IIIA-02 WAGON TIPPLER

PAGE 7 OF 7

PART - B SUB-SECTION-IIIA-03 BRAKES & CLAMPS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

BRAKES AND CLAMPS 1.00.00 1.01.00 BRAKES AND CLAMPS GENERAL Brakes shall be provided for decelerating of driven equipment/conveyors as per requirement. Rail clamps shall be provided for various mobile machines traveling on rails. 1.01.01 STANDARDS The design, manufacture, inspection and testing of Brakes & Clamps shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Brakes & Clamps shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 1.02.00 1.02.01 DESIGN REQUIREMENT Electro Hydraulic Thruster Brakes/Disc Brakes The necessary Electro Hydraulic Thruster (AC) brakes / disc brakes, totally enclosed and fail safe, shall be provided as required for various equipments. Braking torque shall be adjustable from 0 to 100% of rated braking torque. The thruster brake shall be actuated by compression springs. 1.02.02 Clamps Electro-hydraulic thruster and manual rail clamp shall be designed for holding the machine stationary. Electro-hydraulic thruster and manual rail clamp shall be actuated by compression springs, the spring shall apply the clamping force directly on the Rail clamp mechanism once power supply is cut-off. The force transmission mechanism from spring to rail clamp faces shall be very simple with minimum linkages. 1.03.00 1.03.01 1.03.02 CONSTRUCTION REQUIREMENT Thruster Brakes The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be provided for brake applied/released positions. The windings shall be provided with class-B insulation suitable for 415V 10% at 50 Hz 5% and combined variation of 10%. Brake lining shall be asbestos with inter woven brass wires capable of withstanding 200C temperature.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-03 BRAKES AND CLAMPS

PAGE 1 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS Clamps Electro Hydraulic thruster shall be fitted directly above spring. Rail clamp shall be provided between the two travel wheels. Further, limit switches shall be provided for Rail clamp ENGAGED and DISENGAGED signals. Minimum clearance between the Rail clamp face and rail surface shall be 50mm. However, this clearance may not be uniform for both the faces of Rail clamp throughout the length of rails. Rail clamp shall operate satisfactorily under this condition without the need for any adjustments.

1.03.03 1.03.04 1.03.05

1.03.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-03 BRAKES AND CLAMPS

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET: BRAKES AND CLAMPS

1.0.0 1.1.0

GENERAL Brakes (i) For decelerating of conveyors & rotating equipments. Brakes are mandatory for H.T. drives involving scoop type coupling.

(ii)

1.2.0

Rail Clamps

For various mobile equipment travelling on rails (as applicable).

2.0.0 2.1.0 2.1.1

DESIGN & CONSTRUCTION REQUIREMENT Brakes Type Electro Hydraulic Thruster brakes A.C. operated or Disc brakes. Adjustable from 0 to 100% of rated braking torque. Operated directly by spring Asbestos with interwoven brass wires. 200 degree C. Class-B insulation, IP-65 protection.

2.1.2

Braking Torque

2.1.3 2.1.4 2.1.5 2.1.6 2.2.0 2.2.1 2.2.2

Brake Shoes Shoe lining Max. Temperature for shoe lining Thrustor Clamps Rail Clamp support Limit Switches

Independent from the rails. ENGAGED signals. & "DISENGAGED

2.2.3

Clearance between Rail clamp face Minimum 50 mm & Rail surface Material for Rail clamp Mechanism Thruster Type Forged steel Class-B insulation, IP-65 Protection Electro hydraulic thruster, manual

2.2.4 2.2.5 2.2.6

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-03 BRAKES AND CLAMPS

PAGE 3 OF 3

PART - B SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

MONORAILS AND HOISTS 1.00.00 1.01.00 MONORAILS AND HOISTS GENERAL Suitable handling arrangements shall be provided for all equipments included in Contractors scope to transfer the equipment to maintenance area within the building and/or to transfer the equipment outside the building upto ground level for further transportation by the Employer. For this purpose Contractor shall provide monorails and hoist blocks with cross travel facility. 1.01.01 CODES AND STANDARDS The design, manufacture, inspection and testing of Monorails and Hoists shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Monorails & Hoists shall conform to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3938 : Specification for Electric Wire Rope Hoist IS:3832 : Chain pulley blocks IS:2429 : Round steel short link chain IS:6216 :Short link chain grade 80 IS:8610 :Points hooks with shank for general engineering purposes IS:210 : Cast Iron Castings 1.02.00 1.02.01 DESIGN REQUIREMENTS For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with the exception of hoists for GTU and bend pulleys motor operated hoist blocks for both long travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both travel and lift. All monorails coming out of the buildings shall be provided with electric hoist blocks, irrespective of load and lift. Minimum 3 meter length of Cantilever from edge of building/cladding, shall be provided in monorails coming out of the building to lower the equipment to ground level clearing the

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

PAGE 1 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS building sidewalls / cladding and any other facilities beneath the floor upto ground level.

1.02.02

The exact lift/travel and the number of the hoisting mechanisms and the mode of lifting equipments to various floors of the buildings shall be as decided by the employer at the time of detailed engineering. Clear height shall be maintained when handling one equipment over other, in such case dismantling of any equipment shall not be permitted. The center line of monorail shall not deviate by more than 500 mm from the center of gravity of any equipment that is to be lifted. Contractor shall take clear note of the fact that the number and monorail hoisting systems shall also be decided considering the movement of the equipment being lifted over/by the side of other equipments without removing the later. The necessary levels of floors in various buildings shall be decided considering the above requirement. Monorails shall be extended outside the building to handle the equipment to ground level. For monorail/hoist routed inside the buildings, suitable machinery well and removable handrailing and grating shall be provided on various floors of buildings, as necessary, to handle the equipment. Electrically operated monogirder type hoists shall consist of following major components. (a.) Electrically operated trolley complete with drive motor (Trolley travel speed maximum 15 m/min.). Hoist cable, hoisting block and hooks complete with drive motor (Hoisting speed maximum 6m/min.). Limit switch to prevent overhoisting, over lowering and over travel. Festoon arrangement of feeding power to trolley assembly. Erection hardware. Pendent control station suspended from hoist. Control panel mounted on wall.

1.02.03

1.02.04

(b.)

(c.) (d.) (e.) (f.) (g.) 1.02.05

The electric hoist shall be designed and constructed in accordance with the latest revision of IS:3938 and shall be suitable for duty class 2. For electric hoists, trolley movement and hoisting shall be effected by using two separate motors. Motors shall be as per technical requirements discussed elsewhere. However the motors shall be suitable for 150 starts per hour at 40% CDF.

1.02.06

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SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

PAGE 2 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS Trolley for motorized / manual cross travel shall be designed to accommodate a wide range of I beams and shall be capable of travelling on straight as well as curved monorails with the design being such to maintain uniform distribution of pressure on the flanges. Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which shall be driven through motor. Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not acceptable. Minimum number of falls of rope shall be four (4). All gears and pinions shall be of hardened and tempered steel with machine cut teeth in metric modules. Surface hardening of steel is not acceptable. All running shafts and wheels shall be fitted with ball / roller bearings with a rated life not less than 20 years based on equivalent running time as per IS:3938. An electromechanical brake shall be provided for hoisting as well as cross travel. Brake lining shall be of asbestos. Cast iron parts, wherever used, shall be of minimum grade 30, IS:210. All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216 grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be as per IS: 8610 & with antifriction bearing. All hoists/chain pulley blocks shall be selected to have minimum headroom and shall be selected to lift heaviest piece of equipment. Further, it shall be possible to handle any equipment without disturbing other equipment. The hand chain wheels shall be of cast steel, the wheels shall be with flanges and designed to ensure effective operation of hand chain. Further, suitable local brake shall be provided as per IS:3832 to arrest and sustain loads in all working positions. The velocity rates, effort on chain required to raise the safe working load and travel and speed shall be within the limit specified in IS:3832. Proof load test shall be carried out as per IS:3832. Balance requirements shall be as discussed in earlier clauses pertaining to electric hoists. Hoist for Gravity Take up arrangement and bend pulley. For handling bend pulley, take-up pulley and counter weights following hoisting arrangement shall be provided:

1.02.07

1.02.08

1.02.09

1.02.10

1.02.11

1.02.12

1.02.13 1.02.14

1.02.15

1.02.16

1.02.17

1.02.18

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

PAGE 3 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS (1) For handling bend pulleys, hooks of adequate capacity shall be provided at the top of gallery. Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity shall also be provided for the entire coal handling plant for handling bend pulleys. For handling take-up pulleys, manual hoist along with mono rail beam of adequate capacity having cross travel, arrangement shall be provided at bottom of gallery to handle take-up pulley only of conveyors. For handling take-up weight, a separate manual hoist with mono rail beam of adequate capacity shall be provided to hold complete counter weight (inclusive of all counter weight blocks). This hoist shall be provided for holding the counter weight and shall be located in the zone of counter weight travel.

(2)

(3)

1.03.00 1.03.01

CONSTRUCTION REQUIREMENT The hoist mechanism shall consist of a grooved rope drum driven by electric motor through gears. Each end of the rope shall be anchored to the drum in such a way as the anchorage is readily available for maintenance. Each rope shall have two (2) full turns of the drum when the hook is at its lowest position and one (1) spare groove when the hook is at its highest position. The leading rope taken by the drum should not slope sideways when slack and it should not be caught between the gear wheel. Rope drum, gear box, block etc. should be fabricated out of weldable quality steel. Trolley wheels shall be of single flange type in the taper treads. The wheels shall be mounted on antifriction bearings and shall be easily removable for repair/ replacement. The load hook shall be swiveling type forged circular shank section and shall confirm to IS:8610. All gears and bearings shall be lubricated by grease. All lubricating points shall be grouped together in easily accessible position. The bottom block shall be of enclosed type and shall have guard against rope jamming in normal use. It shall have standard forged swivel shank hook fitted on antifriction thrust bearing. Lock to prevent hook from rotation and locking arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom block shall be provided with antifriction bearings. All parts requiring replacement/inspection/lubrication shall be accessible without need for dismantling of other parts/structures. All components of hoists of identical capacity and duty shall be interchangeable.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

1.03.02 1.03.03

1.03.04

1.03.05

1.03.06

1.03.07

1.03.08

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 4 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS Hoists shall have permanent inscription in English on each side readily recognizable from floor level stating safe working load. Pendant shall be provided with flourscent up/down/forward/reverse travel push buttons and indicating lamps. Its power supply shall be limited to 24V AC. The control panel shall be wall mounted type & easily approachable from the floor by a standing man. For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with ladder shall be provided for each electrical hoist. Inline magnetic separator shall have motorised hoist for handling / maintenance purpose. Each suspended magnet shall be provided with a dedicated motorised trolley.

1.03.09

1.03.10

1.03.11

1.03.12

1.03.13

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SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

PAGE 5 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : MONORAILS AND HOISTS 1.0.0 1.1.0 GENERAL Functional Requirement : To transfer equipments to maintenance area or outside the building.

2.0.0 2.1.0 2.1.1

DESIGN & CONSTRUCTION REQUIREMENT Hoists Drive (i) More than 2.0 tonne or more than Motor driven for both travel & lift. 10.0 m lift or hoists coming out-side the buildings

(ii) Other hoists including the hoists for Manual for both travel & lift. handling takeup pulley and takeup weight 2.1.2 Maximum trolley travel speed for electric 15m/min hoists Maximum Hoisting speed for electric 6 m/min hoists Drive Motors No. of starts for drive motor Wire Rope (i) Type/Construction Pre-formed type, hemp cored, regular lay 6/36 construction 160-175 kgf/sq. mm SQIM, Separate for travel & lift 150 starts/hr at 40% CDF

2.1.3

2.1.4 2.1.5 2.1.6

(ii) 2.1.7

Breaking Strength

Bearing (i) (ii) Type Life Ball/Roller bearing 20 years Electro Mechanical asbestos lining. type with

2.1.8

Brake

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SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

PAGE 6 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.1.9

Load Hook

Swiveling type shank section. Class 2

forged

circular

2.1.10 2.2.0 2.2.1 2.2.2

Duty Monorail location/layout Cross section Distance between C/L of monorail & C.G. of equipment to be lifted Power Cables Support Manual Hoists Maximum manual effort for operation.

I beam Maximum 500 mm

2.2.3 2.3.0 2.3.1

Festoon type arrangement

30 Kg

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-04 MONORAILS AND HOISTS

PAGE 7 OF 7

PART - B SUB-SECTION-IIIA-05 CHUTES & HOPPERS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CHUTES AND HOPPERS 1.00.00 GENERAL Chutes & Hoppers, flap gates and rack & pinion gates shall be furnished integral with coal handling system being supplied. All necessary accessories, electricals etc. shall be provided to ensure proper flow/storage/bifurcation of coal as per system requirements. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Chutes & Hoppers shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The chutes, hoppers shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:4682 :Code of practice for lining of vessels and equipment for chemical processes. IS:226 : Structural Steel (Standard Quality) IS:11592 : Code of practice for selection and design of Belt Conveyors. 1.02.00 1.02.01 1.02.02 1.02.03 DESIGN AND CONSTRUCTION Chutes, Hoppers The minimum valley angle of chutes shall be 60 degrees from horizontal. Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without any accumulation anywhere. Complete chute work above the drive floor for conveyors provided with In-line belt magnetic separators shall be of 10 mm thick SS - 304 in the zone of magnetic field. Direct impact of material on conveyor belt shall be avoided by providing an inclined surface at 60 degrees valley angle at the feeding point to guide the material in the direction of belt travel. Further, chute construction below flap gate shaft shall be such that there will not be any accumulation of coal dust between chute and flap gate in that zone.

1.02.04

1.02.05

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 1 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD / LSLAS07 or equivalent material. Long chutes guiding flow from considerable height shall be provided with impact plates wherever change in direction of flow takes place. Hinged inspection doors of leak proof construction shall be provided for access/ maintenance purpose, at approachable heights for chutes and flap gates. All chutes should have one inspection door at every floor and for the ones in between the floors (more then 1.5 meter above the operating floor level) suitable access for trouble free maintenance shall be provided. For sealing of inspection doors labyrinth type arrangement to be provided. In addition to positive locking arrangement, mounting bolts, to tighten the door further against rubber shall also be provided. Bottom side of the chutes on which the coal slides shall be welded to the side plates to form a trough. Bottom sides along with its adjacent sides shall be flanged and made from TISCRAL or equivalent material of 20 mm thickness. The non-striking surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough. Inside welding shall be provided in the corners for permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be joined through bolted flange connection to form the chute legs. Adequate care shall be taken to locate the flange joint away from floor level for easy maintenance. Bolted flange joints shall be of dust tight construction and necessary sealing material shall be provided in all the flange connections for adequate sealing. Complete chute work in the region of flap gates shall be fabricated from 20 thk TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While finalising the chute work inside the building, arrangement for shifting and replacing chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be provided. While fabricating the chute, no welds in between shall be allowed.

1.02.06

1.02.07

1.02.08

Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors with suitable access to them. Further, serrated rubber seal shall also be provided at the very inlet of head chute to minimize dust nuisance. Separate maintenance sealed door shall be provided for access to belt cleaners in head pulley hood, flap gates for maintenance and inspection doors shall be of hinged with positive locking facility. (a) There should be sufficient clear space to install, remove and maintain scrappers without cutting structures. Slope of plates below scrappers to direct coal scrapped by these to the main stream shall be 60O min.

1.02.09

1.02.10

(b)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 2 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS Skirt Boards Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable Skirt Plates shall be provided for entire feeding chute and shall be extended minimum 3 m ahead of front edge of chute and 500 mm beyond rear edge of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In the belts where coal of appreciable lump size (250 mm) is being conveyed, the gap between the bottom of the skirt board and the belt shall be made to increase uniformly in the direction of belt travel. The height of the skirt boards shall be sufficient to contain the material volume as it is loaded on the belt and shall not be less than 750 mm. The skirt plates shall be fitted with modular segmented and replaceable rubber skirting pads having facility of adjusting the pressure on the belt conveyor and shall have provision of on line removal for the purpose of easy maintenance. Such segmented rubber pads with its holding down adjustment arrangements shall be of proven design. The edges of segmented pads shall be installed at an angle for providing a better seal. All care shall be taken while designing, to combine good sealing with minimum belt wear. Flap Gates The motor operated 2 position flap gates shall be provided in transfer chutes as specified and shall be complete with electrically operated actuators. The gates shall be of robust construction and suitable for trouble free operation. The face of the flap gate shall be made out of 20 mm thick TISCRAL or equivalent material. The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at rated load and thrust. The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flap gates against the moving weight of coal and/or flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. Lever arm shall be provided between actuator and flap gate shaft for obtaining required thrust. The actuators shall be capable of preventing any over travel. Suitable travel dependent limit switches controlling the travel of the flap gates on either direction shall be furnished. These shall be placed internal to the drive unit and shall be completely dust-proof. The limit switches shall be capable of adjustments to vary the total length of travel of the gates. Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip off the actuator motor in case of excessive thrust due to jamming of the gates

1.03.00 1.03.01

1.04.00 1.04.01

1.04.02

1.04.03

1.04.04

1.04.05

1.04.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 3 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS during its travel in either direction. The same shall also be integral to the drive unit and shall be dust proof.

1.04.07

Provision for alternative manual operation shall also be made using declutchable hand wheel. The diameter of hand wheel shall be selected considering convenient force to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be provided. Manual effort required to operation the flap gate shall not exceed 25 kg. All the two way chutes, one way of which is leading towards the future conveyor shall be provided with blind flange. All the actuators in the plant should be selected based on heaviest loading, but the rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case. Suitable stiffening arrangement shall be provided between the two faces of the gate plate. At the end of the travel the total length of edge of the flap gate shall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate. Maximum feasible counterweights shall be provided for better utilisation of system. However, for calculation of thrust required, the benefit of counterweight shall not be taken into considerations. Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for regreasing shall be provided. For standardization purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thrust as calculated for various locations. Flap gate actuator as a whole and individual component wise shall be completely interchangeable for all locations. The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be suitable for motor stalled condition and associated twisting. Approach/maintenance platforms complete with the chequered plate floor, hand rails, ladders etc. shall be provided for all flap gates. The platforms shall be extended for access to dust & debris chute inside buildings. Shaft & flap gate shall be tightly fitted to each other. Rack & Pinion Gates Rotary actuator operated rack and pinion gates shall be provided at various locations as specified. The gate shall be mounted such that coal load does not act vertically on gate.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B

1.04.08

1.04.09

1.04.10

1.04.11

1.04.12

1.04.13

1.04.14

1.04.15

1.04.16 1.05.00 1.05.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 4 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS Suitable manually operated rod gates shall be provided over rack and pinion gates for their easy operation and maintenance. The rack and pinion gate shall be guided properly and suitable rollers with bearings sealed for life and dust proof shall be provided. The rack and pinion gates shall be of mild steel construction with liner plate of 10 mm thick TISCRAL or equivalent material. The gates shall be operated by means of double rack and pinion. The material for rack & pinion wheel shall be cast steel and shaft shall be EN.-8. Provision for alternative manual operation of motorized rack and pinion gates shall also be made. Limit switch for safety of person operating the hand wheel shall be provided. Manual effort required to operate the rack and pinion gate shall not exceed 25 kg. Approach/maintenance platforms complete with chequered plate floor, hand railings, ladder etc. shall be provided for all gates.

1.05.02

1.05.03

1.05.04

1.05.05

1.05.06 1.05.07

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 5 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : CHUTES AND HOPPERS 1.0.0 1.0.1 2.0.0 2.1.0 2.1.1 2.1.2 GENERAL Coal Parameters DESIGN & CONSTRUCTION Chutes & Hoppers Minimum Valley Angle Material : (a) Chute work Sliding zones & adjacent sides No striking/ Non sliding zones 20 mm thk. TISCRAL / equivalent 10 mm thk MS thk. 60 degrees As specified elsewhere

Chute with valley angle 80 degree All four sides of 20 mm and above TISCRAL/equivalent material In the zone of magnetic field of SS-304 10 mm thk. ILMS (chute above floor over which ILMS is suspended) In the zone of flap gates Discharge pulleys 2.1.3 Inspection Doors Hoods over

20 thk TISCRAL/ equivalent material head 4 mm thk M.S. with rubber curtain

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

2.1.4

Chute Construction (a) Corners One face of removable bolted flange connection Flange joints construction Min. M-16 Not more than 125 mm C/C Bolts with plain spring washers of dust tight

(b)

Joints Bolted

(c) (d) (e)

Bolt size Bolts spacing Fixing Arrangement

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 6 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.2.0 2.2.1

Skirt Boards Length Entire feeding chute and shall be extended min. 3 m ahead of front edge of chute and 500 mm beyond rear edge of chute. Not less than 750 mm 2/3 of belt width Min. 10 thk TISCRAL/equivalent 6 mm thk M.S.

2.2.2 2.2.3

Height Width Side plate Top cover

2.3.0 2.3.1 2.3.2

Flap Gate Type Travel Linear actuator operated, 2 position 60 to 70 deg. (with limit switches on both sides).

2.3.3

Automatic operation (i) Drive Dust tight motor driven with suitable linkages 2500 kg with 1 m lever arm 15 (with 10 consecutive switchings) Travel and Thrust dependent limit Switches.

(ii) (iii) (iv)

Minimum Actuator Rating No. of Operation / Hr Protection

2.4.4

Manual Operation (a) Maximum effort Convenient for single operator by declutchable hand wheel regardless of electrical power. 500 mm

(b)

Minimum Handwheel Diameter

2.4.5

Flap gate shaft (i) (ii) Diameter minimum Material 130 mm EN-8

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 7 OF 8

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.5.0

Rack & Pinion Gate

Rotary actuator operated provision of manual operation Mild Steel 10 mm thick TISCRAL/equivalent Cast Steel EN-8 50 sec.(Approx) 25 kgs. Both travel & thrust dependent 130 mm 15 (with 10 consecutive)

with

2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9

Material Liner Rack & Pinion Shaft Max. time for closing/ opening Maximum manual effort Limit switches Main shaft dia. Minimum No. of Operations /hr.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-05 CHUTES AND HOPPERS

PAGE 8 OF 8

PART - B SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

BELT CONVEYOR SYSTEM 1.00.00 GENERAL All Belt Conveyors shall be furnished and erected along with necessary supporting structures, platforms, on ground or overhead galleries, trestle structure with foundation footings, carrying and return idlers, automatic take-ups, pulleys, drive motors with suitable reduction units and couplings, belting, feeder hoppers, transfer chutes, flap gates, hydraulic couplings and other necessary accessories as per scope specified elsewhere. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of the Belt Conveyor System shall comply with all the currently applicable statues, regulations and safety codes in the locality where the equipment is to be installed. The belt conveyor system shall confirm to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. Belt Conveyors for Bulk Manufacturers Association. Materials published by Conveyor Equipment

IS:7155 : Codes of Practice for Conveyor Safety. IS:1891 (Part-I) : General Purpose Belting IS:8598 : Idlers and Idler Sets for Belt Conveyors IS:4009 (Part-II) : Conical Head Grease Nipples IS:8531: Pulleys for Belt Conveyors. IS:226 : Structural Steel (Standard Quality) IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical Processes. IS:11592 :Code of practice for selection and design of Belt Conveyors. CAN / CASA - M422 M87 : Canadian standard association. 1.02.00 1.02.01 DESIGN REQUIREMENT Design of belt conveyor system shall be suitable for coal parameters specified elsewhere.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 1 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS Slopes of conveyors, wherever applicable, shall not exceed 16 deg. depending on the lump size, and other governing factors. The guaranteed capacity of all conveyors shall be the rated capacity. All conveyors shall be designed for 110% of rated capacity. Design capacity of the conveyor system shall be considered for the selection of belt width, belt speed and the continuous motor rating at 50 deg C Ambient. The drive chain equipments for various belt conveyor systems shall consist of drive motors, fluid couplings, gear reduction units, low speed flexible couplings and pulleys. For the ratings of various equipments as mentioned above in the drive chain of conveyor systems relevant sections of this specification shall be referred to. Conveyors and belt feeders shall be provided with electro hydraulic thrustor brakes or fly wheels to adjust the coasting time of conveyors such that there will not be any build up of material in the chutes. Further conveyor shall come to halt as early as possible. All conveyors with HT drives (except bunker conveyors) shall be provided with brakes. Remote operated Movable discharge pulleys and movable belt feeders shall be provided as per the tender drgs alongwith the complete electrically driven moving mechanism with rails, trolleys, guide roller etc. The complete discharge pulley movement area shall be covered with proper sealing arrangement. Proper brakes and mechanical locks shall be provided to avoid the rushing of the discharge pulley due to load and the design shall prevent over travel of pulley / belt feeder. The discharge chute opening shall be provided with proper handrails for the safety purpose. Suitable rotating strobe lights and siren shall be provided to warn personnel at the time of operation. Suitable arrangement for sensing correct positioning of movable pulley / belt feeder shall be provided which shall be used in protective interlock. Belt conveyor system shall be designed as per the latest edition of Belt Conveyors for Bulk Materials published by Conveyor Equipment Manufacturers Association or equivalent International Standard. CONSTRUCTION REQUIREMENT Belting The belting shall be of either synthetic fabric such as Nylon-Nylon, Steel Cord. etc. with rubber covers of adequate flexibility to give a troughing angle of 35 deg. For all the conveyors the number of plies, cover thickness, factor of safety etc. shall be as per the recommendation of belt manufacturer, but not inferior to the figures as tabulated in data sheet. Idlers Carrying idlers shall be provided with three equal rolls with troughing angle of 35 deg. and 2 deg. forward tilt (except in case of reversible conveyors).
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

1.02.02

1.02.03 1.02.04

1.02.05

1.02.06

1.02.07

1.02.08

1.03.00 1.04.00 1.04.01

1.05.00 1.05.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 2 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS In no case, shall the diameter of the idler roll be less than 152 mm for both carrying side and return side. However for impact idlers roll the steel diameter shall not be less then 139 mm and rubber thickness shall be minimum 25 mm. Roller used in idlers shall be made from ERW steel tube. Wall thickness shall be minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on EN-8 or equivalent material spindles by means of ball bearings of either deep groove type or seize resistant type (SKF/Equivalent), of 30 mm size for carrying idlers and 20 mm size for return idlers. The bearings shall be adequately sealed and lubricated for life. The rolls shall be supported from fabricated steel brackets. Fixing arrangement of rollers with brackets shall be drop-in type. For adjusting the alignment of the idlers, slotted holes shall be provided in idler supporting base plates. Direction of belt travel shall be clearly marked on the brackets of carrying idlers by embossing / punching. Idler rollers shall be waterproof, dust proof and weather proof against a high velocity water jet. All idlers shall be provided with minimum double labyrinth dust seal. Impact idlers used at the loading and transfer point shall be so designed as to avoid direct loading impact, belt damage and excessive punishment to the carrier. The material used in construction of this type of idlers shall be of resilient type. The return idlers for all conveyors shall be single roll type. For conveyors longer than 400m, two roll return idlers with 10 deg. troughing angle shall be provided. The self-aligning idlers shall be direct acting type, complete with actuating rollers fitted with the ball bearings and mounted inclined towards the belt. The idler frame shall be suitably cradled about a vertical pivot, supported in bearing over a fixed plate. Adequate sealing arrangement shall be provided to prevent contamination of the lubricant by dirt and moisture. Transition type troughing idlers shall be used adjacent to all pulleys to permit proper support of the loaded belt near the pulleys without excessive stretch of the belt edges. The transition idlers shall be provided with preferably adjustable concentrator (end) rolls and long center rolls to suit the troughed belt contour between the last regular troughing idler and the adjacent pulleys. The transition length and the number of the transition idlers shall be selected depending upon the tensions, type and size of belt, number of plies and other necessary governing factors. All the conveyors shall be provided with one self cleaning type rubber disc return idler located near the head pulley for cleaning the return belt. Proper arrangement shall be provided in the brackets of all types of idlers for preventing the rollers from coming out of the brackets during normal / abnormal conditions. Belt Cleaners External Belt Cleaner Spring loaded scraper type cleaner with modular segmented and replaceable polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted separately) along with accessories and necessary fines (reject of scrapper) chutes

1.05.02

1.05.03

1.05.04 1.05.05

1.05.06 1.05.07

1.05.08

1.05.09 1.05.10

1.06.00 1.06.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 3 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS shall be provided for all belt conveyors, tripper head pulley and belt feeders at discharge pulleys. The modular units shall be easily replaceable. The scraper assembly shall be easily maintainable from outside without any interference with the chute arrangement and assembly.

1.06.02

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

1.07.00 1.07.01

Belt Take-up Arrangement Automatic take-up of gravity type shall be generally provided with necessary take-up arrangements complete with bend pulleys, take-up pulley, with its supporting / sliding assembly, wire ropes with turn buckle arrangement (to adjust the level) for suspending the separate take - up weight sliding assembly close to the ground, counter weights and other accessories. Suitable guards marked up scale attached to the frame to monitor belt stretch and access/maintenance platforms with handrails all around etc. shall be provided. Adequate access from conveyor gallery/transfer house/ground etc., as the case may be shall be provided to inspect, repair and maintain the gravity take-up arrangement. Guides of take up pulley/counter weights shall be sufficiently strong so that they do not bend during belt snapping. The prime consideration should be to locate the automatic take-ups at a place where these will work best, in relation to the drive, to keep belt tension at a minimum. Other considerations such as available space, maintenance considerations and the economics of the location should also be taken into account while designing. Take up shall not be located over buildings unless indicated in tender drawings. Height of take-up guide structure shall be sufficient to allow the take-up weight movement up and down for all operating conditions of conveyor and to allow minimum two (2) vulcanizing lengths margin in the belt or percentage of conveyor length (2.5% for synthetic belting or 0.5% for steel cord belting) whichever is larger. Suitable guides shall be provided both for take up pulley and take up weight. Two (2) meter safety fencing along with suitable gate and locking arrangement shall be provided around gravity take-up at the base level / ground level. Irrespective of take-up location, the travel zone of take-up weight shall start from a suitable height above ground level. Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in order to avoid damage of the pulley assembly in case of belt snapping. Similar buffer arrangement shall be provided for take-up weight also, in case of, take-up weight travel zone terminating above a building floor. Sandpits of 600 mm deep shall be provided at ground below the take-up weights. In case of double stream conveyors, a partition of 3 mm steel plate shall be provided between the two take-up pulleys along entire travel zone of take-up pulleys. Intermediate platforms shall be provided in the take-up zone for maintenance of take - up pulleys / counter weight.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM PAGE 4 OF 16

1.07.02

1.07.03 1.07.04 1.07.05

1.07.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS Take-up weight shall consist of multi-blocks and not of single block to facilitate adjustment in weight if required during operation. Single heaviest piece shall be suitable for easy handling. Take-up weight block shall be provided with edge protection angle to take care of any damage. Take up weights shall be kept inside a take up weight box and shall be properly anchored / bolted with the main frame, so that the none of the weight shall be loose/free inside the box. The box shall be painted with counter weight and conveyor number and shall have good aesthetic look. Hold Back Devices Suitable hold back devices for preventing running back of the conveyor belt in case of conveyor being stopped in loaded conditions due to power failure or during normal operational delays shall be provided to give positive protection. The hold back shall instantaneously engage without shock and be capable of protecting equipment and personnel. It shall be released instantly when power resumes or the delay is removed. The holdback devices shall be integral with gearbox. Pulleys Pulleys shall be provided as required for various conveyors. In determination of pulley diameter, no account shall be taken of the pulley lagging. The nominal diameter and face width of the pulleys shall be as stated in IS: 8531. The snub pulleys on each conveyor shall be located to provide a belt wrap on the drive pulleys of not less than 210 deg. wrap is envisaged for single snub drive only. All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lagging grooved in diamond pattern. All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain lagging. The rubber to be used for lagging of pulleys shall confirm to specifications listed in data sheet of this section. The rubber lagging of pulleys and method of lagging and testing the same shall conform to IS:4682. The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality). However, for conveyors with in line magnetic separators, the head end pulleys shall have shell and end disc made of non-magnetic stainless steel material. All the pulleys shall be mounted on the forged steel shafts of EN-8 or equivalent material of adequate proportion by taper lock arrangement, running in heavy duty roller bearings with proper greasing arrangement. The plummer blocks for pulleys shall be of horizontally split type construction with minimum (4) nos. bolts holding the two split halves and with min (4) nos. foundation bolts. The plummer blocks shall be dust tight with double labyrinth seals. Conical head shape nipples conforming to IS:4009, suitable drain plug and eye bolt shall be provided. Side covers of plummer blocks shall be heavy duty metallic sheets. No plastic components shall be used.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM PAGE 5 OF 16

1.07.07

1.08.00 1.08.01

1.09.00 1.09.01

1.09.02

1.09.03

1.09.04

1.09.05

1.09.06

1.09.07

1.09.08

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall be provided for all tail pulleys and bend pulleys for safety of operating personnel. Suitable stiffening arrangements shall be provided in all pulleys. For selection of pulley shaft dia of all the pulleys, a margin of atleast 20% shall be considered on the maximum tension at designed Conveyor capacity. Selection of pulley diameter, shell thickness, stiffening and shaft diameter shall be subject to approval of Employer during detailed engineering. Belt Protection Equipment Pull chord Switch Pull chord type (manually reset type) emergency stop switches shall be located on both sides of belt conveyors along the walkways for the entire length of conveyors for emergency stopping of conveyor. The enclosure shall be of cast aluminum with degree of protection IP-65. It shall have a separate terminal box with a separate hinged cover which shall be totally sealed from main box containing actuating mechanism / limit switch etc. Local pull chord actuation shall be provided by means of mechanical flap. Each switch shall have two NO and two NC contacts, which shall be wired out to the terminal block. The terminal block shall have facilities of cable looping. The Contact rating of the switches shall be rated for atleast 5 Amps, breaking at 240 VAC at 0.3 p.f. lagging. Adequate length of rope and all accessories shall be furnished. Pull chord in stone picking area shall be routed inside G.I. pipe of 1 size.

1.09.09 1.09.10

1.10.00 1.10.01

1.10.02

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

1.10.03

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

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 6 OF 16

CLAUSE NO.

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

1.10.04

Chute Blockage Switches One no. chute blockage switch of proven type (subject to approval of the employer) shall be provided at a suitable height on each leg of the conveyors discharge chute, vibrating screening feeders by pass chutes, crusher feeding chutes, tripper discharge and feeding chutes nearest to the skirt boards. Chute blockage switch shall trip the feeding conveyor in case of Chute blockage and protect the feeding conveyor equipment. The switch and its operating arrangement shall be suitable for working in dusty areas. The minimum degree of protection of switch shall be IP-65. Local indication of chute blockage switch actuation shall also be provided. Location of chute block switch shall be such that washing does not affect it.

1.10.05

Sensing arrangement shall be provided in the DDCMIS based control system for detecting the presence of material on the belt which shall in turn be used for operating solenoid valves of dust suppression/extraction system elaborated elsewhere. The arrangement shall detect three events simultaneously as follows: (a.) Belt loaded (b.) Belt running at more than preset speed. (c.) Preset initial start delay.

1.10.06

The terminal boxes of all the belt protection equipments / switches shall be such that all the components / terminals inside are easily accessible for inspection and maintenance without removing the cables / connections / components. Each pull cord and Belt sway switch shall have necessary chip for using in circuit for the identification of the operated switch in main control room. The scheme for switch identification shall be fail safe and shall have all diagnostic features. The scheme shall have facility to by pass one or more switches, if required. Drive Motors Rating of all drive motors of conveyors shall not be less than 120% of the power required at drive motor output shaft at specified design capacity. The motor rating shall be at 50 deg Cent. ambient. Single LT drive motors shall be used for conveyor drive ratings up to 160 KW. For conveyor drive rating beyond 160 KW, single HT drive shall be used for conveyors. Conveyor Bridges All overground and overhead conveyors shall be located in suitably enclosed bridge structure. Structural steel bridges of adequate width and depth (2700 mm clear head room) shall be provided complete with conveyor bottom deck plates, seal
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

1.10.07

1.11.00 1.11.01

1.11.02

1.12.00 1.12.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 7 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS plates, walkways of chequered plates with anti-skid arrangement(s), hand rails (on both sides of each conveyor belt.

1.12.02

The conveyor bridge shall have permanently colour coated steel sheeting covers on roof and both sides, properly screwed or locked to steel structure as required. Adequate provision of windows shall be kept. A continuous slot opening of 500 mm shall be provided on both sides just below the roof sheeting. The floors of outdoor conveyor galleries shall be designed and constructed as follows: Side and central walkways for double streams conveyors shall be 800mm and 1100mm wide respectively. The side walkways for single conveyors shall be 800 mm on one side and 1100mm on the other side. However, if the centre to centre of conveyors or the width of the gallery is decided by some other criteria, maximum walkway widths consistent with gallery sizes shall be provided. In the complete length of conveyor gallery minimum walkway clearance as indicated above is to be maintained inclusive of all equipments and clearances. All conveyors shall be provided with 12 G steel seal plates throughout the length of the conveyor gallery in such a way that complete gallery bottom surface area forms a single water proof floor and no water / coal falls down from conveyor gallery incase of cleaning / washing. It is envisaged to clean the conveyor gallery with water periodically. All the water / coal slurry shall be suitably guided to down comers provided at every trestle. Each downcomer shall lead the coal slurry into a 2 cub meter brick wall tank at ground level having 2 Nos. decanting taps at suitable elevations. Decanted water shall be led to the nearest drain in the Contractors scope. Necessary arrangement shall be provided to avoid choking of downcomers by bigger coal lumps and for cleaning of choked downcomers.

1.12.03

1.12.04 1.12.05 1.12.06

The conveyors shall be provided with continuous decking plate of minimum 3 mm thickness plain steel sheet. Structures and floors shall be so designed as to provide suitable space for routing of 200 NB fire fighting pipe with water, cables and conduits. Steel trestles to support the conveyor bridge shall rest upon concrete foundations to be provided by the Contractor. Complete trestle structures shall also be supplied by the Contractor. Suitable approach/access platforms with hand railings shall be provided to approach the conveyor gallery (like in case of fire) through monkey ladders on the trestles. Suitable wire mesh doors on steel frame construction lockable from outside only shall be provided in the conveyor galleries at these locations. All monkey ladders shall have cage for safety of personnel using them. Independent supports for walkways, conveyor structures shall be provided. The width of conveyor galleries shall be decided by the Contractors depending on the equipments size and the walkway width as specified. However, in no case the width of gallery shall be less than the width specified in tender drawings. Provision shall be kept with platforms and ladders for crossing over the conveyors at approximately every 100m intervals of route length and minimum one per conveyor.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM PAGE 8 OF 16

1.12.07

1.12.08

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS Stone Picking Manual Stone Picking arrangement at a suitable location in the conveyor gallery before the crusher house shall be provided complete with platforms, overhead lighting, handrailings, suitable seating, safety hook & holding arrangement for manual pickers, disposal chutes to ground level etc. Four (4) nos. manual pickers shall be positioned for stone picking. Two (2) nos. manual pickers shall be positioned on each belt. Each manual picker shall cover 3 m long belt stretch adjacent to each other and shall have provision of individual stone collector discharge hood. The picked up stone lumps (upto 600 mm size) shall be collected over the conveyor gallery walkway level from where these stones can be pushed into the hopper/chute upto the ground level. Disposal chute from discharge hoods of length upto 2 meters from ground level shall be provided etc. In the gallery span of stone picking area, the gallery width shall be extended by a minimum of one (1) mtr. on either side to accommodate the stone picking accessories. Accordingly the width of Conveyor Gallery shall be 2 meters wide all along the span of stone picking zone as compare to other gallery span. All trestle coming in the zone of stone picking area shall be suitably encased by RCC. The stone picking area should be suitably barricaded upto 2 mtr. height above ground level so that no damage take place due to stone pile formation and its handling by pay loaders.

1.13.00

1.14.00

Special Cleaning, Protection and Painting All equipments of Wagon Tippler, Conveying & Crushing Plant inclusive of belt conveyor system and technological structures shall be kept clean. Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. All ferrous surfaces shall be applied with one shop coat of 35 micron and one 35 micron site coat of red oxide zinc chromate and two coats, each of 25 micron, synthetic enamel finishing paints unless specified otherwise. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. However for deck plate in track hopper and tunnels, painting specifications mentioned at sub section IIID-01 shall be applicable. The painting colour code shall be provided to the Contractor during detailed engineering.

1.15.00 1.15.01

Belt Vulcanizing Machine Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and shall be of easy-to-handle type. Equipment should be suitable for vulcanizing of entire splice width in single setting. Equipment should be capable of applying uniform pressure over the splice by pneumatic or hydraulic means. Heating element should be preferably of flexible type.

1.15.02 1.15.03

1.15.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 9 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS Belt Jointing Facilities For the purpose of jointing the belting or replacement of belting, following belt facilities shall be provided:

1.16.00

1.16.01 1.16.02

5M X 5M paved area near take up to make joints. Hooks shall be provided on JTs, Conv. Gallery to pull the old belt while replacing the same with new belt.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 10 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : BELT CONVEYOR 1.0.0 1.1.0 GENERAL Design Capacity 110% of rated (guaranteed) capacity for all conveyors. 16 deg 2%

1.2.0 1.3.0 1.4.0

Maximum slope Max. belt Sag between idlers Minimum Radius (i) Concave curve

250 m (In case of travelling trippers, the requirement of minimum radius shall be decided based on the space availability) 50 m As specified elsewhere

(ii) 1.5.0 2.0.0 2.1.0 2.1.1

Convex Curve

Coal Parameters DESIGN & CONSTRUCTION Belting Type

Synthetic Fabric of Nylon / Nylon, Steel Cord. etc. a) Flame test : Conforming to ISO:340 b) Drum Friction and Electrical Surface Resistance Test: Conforming to Canadian standard association CAN / CSA M-422- M87 Grade - C.

2.1.2

Cover Grade

2.1.3

Cover Thickness (without ve tolerances). (a) (b) Face Bottom

Synthetic belting

Steel Cord

5.0 mm (min.) 2.0 mm (min.) Minimum 4 Snub drive

8.0 mm (min.) 5.0 mm (min.)

2.1.4 2.1.5 2.1.6

No. of plies Drive Arrangement Factor of Safety

- 10 (Minimum) for N-N/EP belt. - 7 (minimum) for Steel Cord Belt.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 11 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.1.7

Normal Working tension at design Less than 80% of max. allowable working capacity tension Idlers Type (a) Carrying Three roll, 35 degree troughing, 2 degree forward tilt Single Roll, For conveyors upto 400 m c/c length. Two roll with 10 degree angle for conveyors more than 400 m c/c length Impact type

2.2.0 2.2.1

(b)

Return

(c) 2.2.2

Loading point

Spacing (a) (b) Carrying idlers Return idlers 1.2 m (0.6 m for convex curves). 3.0 m (for convex curves not more than 1.5 m.) Minimum six (6) with 400 mm spacing. troughing At 10 m distance from head & Tail pulleys with intermediate spacing 15m At 10 m distance from Head & Tail pulleys with intermediate spacing 20m. (Not required for conveyors more than 400m c/c long where 2 roll return idlers are provided).

(c) (d)

Loading point Self-aligning idlers

(e)

Self - aligning return idlers

2.2.3

Bearings (a) Carrying Ball Bearings of deep groove type or resistance type of min. 30 mm lubricated for life. Ball Bearings of deep groove type or resistance type of min. 20 mm lubricated for life. seize size, seize size,

(b)

Return

2.2.4

Material (a) Roller ERW Steel tube min. wall thickness 4.0 mm E.N. 8 or equivalent.

(b)

Spindle

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 12 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS Belt Cleaners External Spring loaded scraper type cleaner with modular, segmented and replaceable PU blades with separate main-cleaner & precleaner etc. V-Plough type, mild steel flats with hard rubber strips.

2.3.0 2.3.1

2.3.2

Internal

2.4.0 2.4.1 2.4.2

Belt Take up Type Location Automatic Gravity Type. In relation to the drive to keep belt tension at minimum. To suit all operating conditions or (2.5% for synthetic belt and 0.5% for steel/cord belt) of conveyor center to center length whichever is larger. Further the initial location of take-up shall be decided in such a way that it is possible to carryout min. two (2) nos. Vulcanizing Joints without adding any external belt. Integral with gear Box

2.4.3

Take-up travel

2.5.0 2.6.0 2.6.1

Hold Back Device Pulleys General (for all types of Pulleys) (i) Pulley shaft diameter

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

2.6.2

Drive Pulleys (1) (2) Lagging Lagging thickness Hot lagged with vulcanised natural rubber 12 mm thick grooved in diamond pattern with grooves 6 mm wide x 6 mm deep 210 degrees 0.5% of nominal diameter

(3) (4)

Minimum angle of wrap Maximum Out of roundness

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 13 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS Other pulleys (1) (2) Lagging Lagging thickness Hot lagged with vulcanised natural rubber 12 mm thick plain

2.6.3

2.6.4

Rubber for lagging (1) Type Natural rubber blended with styrene Butadiene rubber. 55 to 65 durometer (Shore A) Over 300% 160-245 kg/cm2 250 mm3 (max.) as per DIN 53516 Max. 1.5 10 kg/cm (minimum)

(2) (3) (4) (5) (6) (7) 2.6.5

Hardness Elongation Strength Abrasion loss Specific Gravity Adhesion Strength

Bearings for Pulleys (1) (2) (3) (4) Type Casing Sealing Lubrication Heavy duty roller type Horizontal Split Type Dust tight with double labyrinth seals. Greasing arrangement with conical head shape nipples. Mild steel conforming IS:226 / IS : 2062 Forged Steel shaft EN-8 or equivalent material.

2.6.6 2.6.7

Pulley Material Shaft Material

2.7.0 2.7.1

Belt Protection Equipment Emergency Stop Switch System (1) (2) (3) Type Location Spacing Pull chord type (manually reset) Both sides of conveyor for entire length Approx 30 m

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 14 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS Belt Sway Switches (1) (2) Type Spacing Limit switches snap action. One pair at 50m interval (Minimum two (2) pairs)

2.7.2

2.7.3

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

2.8.0 2.8.1

Drive Motors Type Three Phase Motors Base mounted Squirrel Cage Induction

2.8.2 2.8.3

Mounting (for conveyors)

Continuous motor rating (Name 120% of actual power requirement at motor plate rating) at 50OC Ambient output shaft at design capacity. Conveyor Bridges Walkways (a) Construction Chequered plate with antiskid arrangement. Chequered plate steps shall be provided where conveyor slope exceeds 10 degrees. (Totally sealed so that no water falls down while washing.) 1100 mm 800 mm (for single conveyors, the width of side walkways shall be 800 mm on one side and 1100 mm on the other)

2.9.0 2.9.1

(b) (c)

Central walkway width Side walkway width

2.9.2

Side Windows (a) (b) (c) Spacing (Center to center) Size Window material 25.0 m on each side (in staggered fashion) 1.2 m x 1.5 m Refer Civil Section

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 15 OF 16

CLAUSE NO.

TECHNICAL REQUIREMENTS Trestles Spacing of monkey ladders on trestles (a) Where height of conveyor gallery (walkway level) is 10 m or more. Where height of conveyor gallery (Walkway level) is less than 10m. : On every trestle

2.10.0 2.10.1

(b)

: On alternate trestle

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-06 BELT CONVEYOR SYSTEM

PAGE 16 OF 16

PART - B SUB-SECTION-IIIA-07 DRIVE EQUIPMENT

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

DRIVE EQUIPMENT 1.00.00 GENERAL Suitable Drive Chain Equipments like electric motors, gearboxes (where applicable), fluid couplings (where applicable), flexible couplings and other accessories shall be provided for all the belt conveyor systems, paddle feeders, crushers, mobile trippers, various pumps of dust suppression/extraction system, fans for ventilation system, monorail electrical hoists and other equipments specified in this specifications. Various requirements as spelt out in the Technical Specifications for individual equipments shall be taken into consideration while designing the associated drive chain equipments. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Drive Equipment shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment in to be installed. The Drive Equipments shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3688 : Dimensions for shaft ends IS:3681: General plan for spur & helical gears IS:7403 : Code of practice for selection of standard worm and helical gear boxes 1.02.00 1.02.01 1.02.02 1.02.03 DESIGN AND CONSTRUCTION REQUIREMENTS GEAR BOXES Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. The gearboxes shall be designed for 24 hours continuous duty. For thermal and mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with cooling coils are not acceptable. The gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction units or spiral bevel speed reduction units conforming to suitable Indian Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical type only. Recommended oil grade shall be compatible with gear internals like material of bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick, drain plug etc.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-07 DRIVE EQUIPMENT

1.02.04

1.02.05

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 1 OF 4

CLAUSE NO.

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

1.02.06 1.02.07

1.02.08

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

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-07 DRIVE EQUIPMENT

PAGE 2 OF 4

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET : DRIVE EQUIPMENT

1.0.0 1.1.0

GENERAL Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for Electric Motors a) For conveyors of belt conveyor systems *120% of actual power at drive motor output shaft at specified design capacity *110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity.

b) Crushers, mono-rail hoists (travel and hoisting), elevators, rack and pinion gates, all the drives in sampling units, drives for various pumps of DS/DE systems, service water systems, cooling water system, potable water system and sump pumps & Ventilation Fans

*The actual power at drive motor output shaft shall be calculated after considering all the losses of down the line equipments of the drive train. 2.0.0 2.1.0 2.1.1 DESIGN & CONSTRUCTION REQUIREMENT Gear Box Type (a) Below 40 KW Helical, worm, bevel as per requirement without cooling coil Helical / bevel helical without cooling coil As per accepted engineering practice / manufacturer's recommendations 50oC Minimum On Machined/Ground Surfaces

(b)

Equal to and Above 40 KW

2.1.2

Service Factor

2.1.3 2.1.4

Ambient temperature for Thermal rating Mounting

2.1.5

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

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-07 DRIVE EQUIPMENT

PAGE 3 OF 4

CLAUSE NO.

TECHNICAL REQUIREMENTS

b) For other equipment @ Service factor X {1.2 times the actual power requirement of the driven equipment } @ Service factor shall include all the components considered by the supplier and should be clearly indicated in manufacturers gear box selection catalogues. 2.1.6 2.1.7 Duty Rating 24 Hrs. Continuous Not less than motor name plate rating

2.2.0 2.2.1 2.2.2 2.3.0

Flexible Couplings Type Rating Fluid Couplings Geared coupling. Not less than motor rating. For all motors having rating more than 40 KW.

2.3.1

Type (a) (b) L.T. Motors H.T. motors Traction type Scoop tube type. Not less than nameplate rating motor

2.3.2

Rating

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-07 DRIVE EQUIPMENT

PAGE 4 OF 4

PART - B SUB-SECTION-IIIA-08 BELT SCALE

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

BELT SCALE
1.00.00 GENERAL Belt weigh scale for measurement of coal flow rate and quantity shall be provided at specified locations. System shall be complete with flow rate indicator, totaliser, control panel etc. 1.01.00 Codes & Standards The design, manufacture, inspection and testing of Belt Scales shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Belt Scales shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. NEMA NEC IS:11547 1.02.00 1.02.01 For electronic circuit enclosures. Electronic weighing in motion system.

Design & Construction Requirements The weigh scale shall be automatic and electronic type. It should be designed for continuous automatic weighing, metering and printing of coal flow. Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4 nos. weighing idlers. It shall have unitised construction for ease of installation and shall be fully floating type (without pivot points). Minimum 4 nos. hermetically sealed load cells of precision strain gauge type shall be applied in tension to support the weigh bridge. The load cells shall have 100% overload protection and shall be structurally safe upto to 250% of rated belt scale capacity. Belt scale shall be electronic microprocessor based with its program stored in nonvolatile memory. It shall be provided with self diagnostic features for trouble shooting of the entire belt scale system. Fully automatic zero and span calibration facility shall be provided. The electronic systems offered by the Contractor shall include all signal conditioning, power amplifiers and printed circuits etc. The printed circuits shall be encapsulated against dust and moisture.

1.02.02

1.02.03

1.02.04

1.02.05 1.02.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-08 BELT SCALES

PAGE 1 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8 digits display scale with reset facility. Complete belt scale system shall be suitable for 50C ambient temperature and 100% relative humidity. It shall be suitable for out door installation in a dusty area. The electronic circuit enclosure, sensors housing shall be dust and watertight. The electronic printed circuits shall be encapsulated with epoxy or other suitable material for protection against dust and moisture. Minimum three years battery back up power failure protection shall be provided. Belt scale shall be designed for a range of 20% to 120% of rated capacity with an accuracy of atleast (+) 0.25 percent throughout its range. Per two (2) belt weighers, the contractor shall furnish one (1) necessary test load chain sets required for calibration and periodic testing of the equipment. The test load chain shall be two idler spaces longer than the weighing length of the weighers and shall be complete with chain reset equipment with weight adding reels of adequate size. The calibrated weight parameter length of the test chain shall be stamped at a suitable location on the body of the equipment. The test chain shall be installed near belt weigher with suitable arrangement for easy mounting/dismounting of chain onto/from conveyor belt. Alternatively, supply of test weights for calibration of belt scales is also acceptable. Local panel for belt scale shall be of sheet metal.

1.02.07

1.02.08

1.02.09 1.02.10

1.02.11

1.02.12

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-08 BELT SCALES

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET : BELT SCALE

1.0.0 1.1.0 1.2.0 2.0.0 2.1.0 2.2.0 2.3.0 2.4.0 2.4.1 2.4.2 2.4.3 2.4.4 2.5.0

GENERAL Ambient Temperature Relative Humidity DESIGN & CONSTRUCTION Type Operation No. of floating idlers Load Cells Type Minimum Nos. Overload protection Structural capacity Flow Rate Indicator Strain gauge type hermetically sealed Four (4) 100 % of rated belt scale capacity 250 % of rated belt scale capacity Electronic Digital Display Minimum 4 digits 8 digit display with reset facility. For entire range of 20% to 120% of rated capacity : Minimum + 0.25% Electronic load cell type Microprocessor based fully automatic Minimum four (4) 50C 100%

2.6.0 2.7.0

Flow totalizer Accuracy

2.8.0 2.8.1 2.8.2

Calibration Automatic Manual (a) Test load chain length Zero & span calibration With test load chain Two idler spaces more than weighing lengths Complete with weight adding facility.

(b)

Chain reel equipment

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-08 BELT SCALES

PAGE 3 OF 3

PART - B SUB-SECTION-IIIA-09 DUST CONTROL & MISCELLANEOUS SYSTEM

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

DUST CONTROL AND MISCELLANEOUS SYSTEM 1.00.00 1.01.00 1.01.01 GENERAL INTENT OF SPECIFICATION The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete, Dust Control and Miscellaneous Systems as specified hereinafter required for the Coal Handling Plant. The Contractor shall refer to the other sections and scheme indicated in the tender drawings to appraise himself of the work and scope of supply of the other Contractors/Employer's and shall coordinate his work with the work of other Contractors. 1.01.02 1.01.03 General Information/Description Dust Control System The dust control system to be furnished under this specification is required for control of fugitive dust emissions from dust generation points such as transfer points (JT), feeders, crushers etc. Dust control is achieved by dust suppression/extraction system. Contractor shall guarantee and offer dust control system which shall not allow a dust concentration in the ambient air inside the buildings more than acceptable limits as per Employer approved guidelines or any internationally recognized hygienic Standards/Codes. The Capacity of dust control system specified elsewhere is for Contractors guidance only. Contractor shall provide adequately sized fool proof dust control systems the performance of which should be guaranteed by the Contractor. However, the capacity of the offered system shall not be less than the specified values. Further, for computation of design capacity of the pumps, permanent recirculation lines as shown in tender drawings shall also be considered. 1.01.04 Miscellaneous Systems Service water system, potable water system, cooling water system & sump pumps shall be provided as specified elsewhere in this specification and as indicated in tender drawings. 1.02.00 1.02.01 Dust Suppression System (a) Plain Water Dust Suppression System Complete with water supply system, piping, spray heads, pumps, drive motors with canopy (wherever required), couplings with enclosure, electricals, supporting structures, approach/maintenance platforms, handling for equipment, civil and structural works and necessary accessories
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

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CLAUSE NO.

TECHNICAL REQUIREMENTS (b) Dry Fog Type Dust Suppression System Complete with water supply system, compressed air system, pressure regulating units, flow activation system, necessary instrumentation for auto & manual operation, drives, pumps, maintenance platforms, alongwith associates civil/structures & electrical works.

1.02.02

Sump Pump 2x100% sump pumps alongwith level switches and piping up to nearest Employers 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.

1.02.03

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

1.02.04

Pipings, Fittings, Valves and Specialities The material to be supplied for completing the pipe work shall include but not be limited to the following: (1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions, couplings, caps, blank flanges, saddles etc. necessary for making reliable piping system. Gaskets, ring joints, jointing material etc. as required. Instrument tapping connections, stubs. Gate / plug, globe and check valves to start/stop, regulate and to prevent back flow. Duplex Strainers. Anchors, hangers and supports as required including secondary steel embedment etc. Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well as for terminal points. The entire water piping of DS / SW / PW / CW / DE system shall be routed/supported on concrete pedestal and conveyor galleries. Wherever the layout does not permit the pipes to be routed over ground, the same shall be buried in conformity to the relevant standards & shall be provided with
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS PAGE 2 OF 18

(2) (3) (4)

(5) (6)

(7)

(8)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS necessary protective coating as per relevant standards and as specified elsewhere in the specification. (9) (10) (11) Painting, anti-corrosive coatings etc. as necessary. Welding electrodes and welding rods. The area around storage tanks, strainers, valves etc. (located out side pump house) shall be paved.

1.03.00

Terminal Points Employer shall provide supply of water for dust suppression/extraction system, service water, potable water at terminal point as elaborated elsewhere. Beyond the terminal point, the complete pipe work for water & air along with associated valves, specialties, instruments, fittings and supports, pumps, tanks, etc. as required for the satisfactory operation of dust control, service water, potable water, cooling water & dust extraction systems shall be furnished by the Contractor.

1.04.00

Codes and Standards The design, manufacture, inspection and testing of Dust Control & Miscellaneous Systems shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Dust Control & Miscellaneous Systems shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:778 : Gun Metal gate, globe & check valves for general purpose. 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. BS: 5169 & BS:1123 : Air Receivers. BS: 5312 CI Check Valve BS: 5150 CI Gate Valve

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 3 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS BS: 5152 CI Glove Valve ANSI B 31.1:Code for pressure piping. Hydraulic institute Standards of U.S.A.

1.05.00

DESIGN REQUIREMENT Dry Fog Dust Suppression

1.05.01

At specified locations dry fog dust suppression system shall be provided which comprises spray nozzles discharging plain water & air in a fine spray to form dry fog to capture air borne dust particles and direct them into the main coal flow. This dry fog shall be discharged through spray heads at the dust suppression zones. The dry fog dust suppression system shall consist of the following: (a) Fogging system & controls consisting of: (i) (ii) (iii) (iv) (b) Spray bar assemblies. Pressure regulating units Flow activation system Instrumentation for auto spray

Compressed air system consisting of: (i) Two (2) nos. one no. working and one (1) no. standby air compressors (screw type) for each group of dry fog dust suppression system, along with air receivers as specified elsewhere. Air receivers Various instrumentation & valves.

(ii) (iii) 1.05.02

Wagon Tippler Dust Suppression The dust suppression system for the wagon tippler shall consist of two (2) zone headers, each of sufficient length routed on each side. Each nozzle header shall be provided with adequate number of spray nozzles spaced at 500 mm interval. Further, at the wagon tippler, the water spray shall be of fogging type with a minimum pressure of 4.5 kg/sq.cm(g) at spray nozzle inlet. It should be possible to operate all zones simultaneously.

1.05.03

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

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 4 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Sump Pumps Sump pumps alongwith level switches & piping upto nearest Employer's drain (max upto 50.0 mtrs. from outside the building) shall be provided at all locations wherever natural drainage is not possible. The capacity of each pump shall not be less than 50 M3/hr. Minimum 10% margin on capacity and 20% margin on computed head shall be considered for selection of pumps. Size of the drain pit shall not be less than 2.0 meters x 2.0 meters x 1.8 meters deep. One no. of settling pit shall also be provided before sump pit so that water without heavy coal particles goes into sump pump pit. High and low level switches shall be provided in the sump pump pit.

1.05.04

1.05.05

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

1.05.06

Potable water (PW) system Potable water connections are to be provided in all junction towers, wagon tippler top, crusher house and all control rooms/MCC rooms and toilets etc. Water shall be drawn from the water storage tank by electric motor driven pumps and discharged via a pipe work system to the overhead drinking water storage PVC tanks of 2500 litres capacities. The drinking water storage tanks shall have provision for maintenance & drain.

1.05.07

Hoists with monorail of adequate capacity shall be provided in the service water/dust suppression/potable water pump houses. Wet Type Dust Extraction System Bidder shall provide wet type dust extraction system for Vibrating Grizzly Screen and Belt Feeder in crusher house. The dust extraction system shall be of either Venturi scrubber system or cyclone separator system. One independent dust extraction system for each stream shall be provided (Total 2 nos. system to be provided). Bidder may provide multiple Units in each of the independent dust extraction system as per his design.

1.05.08

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 5 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Venturi Scrubber System Venturi scrubber type wet dust collection system shall be provided at crusher house for extracting the dust from vibrating screening feeders & belt feeders. The system shall operate on the principle of mixing of dust laden air with water by collision in the venturi throat forming a mass of larger particles for successful collection in the cyclones. The scrubber unit shall have a design for built in collection of the damp dust in a sedimentation tank which shall be discharged automatically at periodic intervals (time setting variable) into an additional ground based settlement pit from which only clear water shall be led by drain line (by bidder) upto coal slurry pond. The scrubber unit shall be of minimum maintenance type design. The system shall be complete with venturi unit, water pockets, risers, circulating water pumps, throttling valve, pressure gauges, all associated valves/accessories, baffles, reducing discs, partition plates, cyclones, discharge pipe, inlet, deflectors, inspection doors of dust light/air tight construction, sedimentation tank, float control valve, overflow trap, quick filling/discharge connection, duplex structures, automatic sludge disposal arrangement. Further, the dust sedimentation tank with the scrubber shall have water level maintained inside if by means of float valves. Also water overflow with trap shall be provided. Requisite water shall be circulated in the unit by means of circulating pump located outside this scrubber. All items of scrubber exposed to water shall be spray galvanized. Min. 6mm thick M.S. plate shall be used for tanks. Pressure drop through the scrubber unit shall not exceed the range of 180 mm w.c. An external monometer drop during operation. The system shall be designed with min. consumption of slurry water. The dust collection efficiency shall be 95% down the 10 micron size.

1.05.08.01

1.05.08.02

Arrangement shall be provided in the slurry discharge system for separating dust and water and discharging only clear water to the coal slurry pond. The dust shall be removed manually for subsequent transportation to yard. All materials including piping, valves, trenches etc. required for the satisfactory operation of aforesaid removal system shall be included in bidders scope. Exhaust Fans : The construction features of fan shall be same as specified elsewhere in the specification.

1.05.08.03

1.05.08.04

Dust Collection Hood: (i) The hood connections shall be designed for collection of dusty air from various coal transfer, vibrating grizzly feeders, transfer chutes and other coal dust generating points.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 6 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS (ii) Centre line of the hoods shall be located at the point of generation of maximum dust. The hoods shall be adequately sized to collect all dusty air generated at the point. Velocity in the hood must not be so high as to draw larger size particles unnecessarily. At all suction hoods (except for bunker dust extraction units) damper shall be provided. The hoods shall be made of MS plate of adequate thickness.

(iii)

(iv)

(v) 1.05.08.05

Ducting (i) The ducts for conveying dusty air shall be of round shape and of streamline appearance. The velocity of air in the duct shall be high enough (in the range of 18 to 21 metres/sec.) to transport in the suspended dust in the air. Tentative layout of ducting shall be furnished by the Bidder along with the offer. Flexible connections shall be provided at the duct connections to inlet and discharge of the fans. All flexible connections shall be non-collapsible type and their length shall be kept to a minimum. Duct supports shall be provided as per stipulations here under : Diameter of duct Less than 200 mm More than 200 mm (vi) (vii) Spacing of support Maximum 3.00 metre Maximum 2.50 metre

(ii)

(iii)

(iv)

(v)

Electrically operated dampers shall be provided at all dust extraction points. The ducting shall be made of MS Sheet with thickness not less than 14 gauge.

1.05.08.06

Suitable platform and ladders shall be provided for carrying out maintenance of dust separator / collection tower. CONSTRUCTION REQUIREMENT Water Supply Pumps Water supply pumps shall be provided as required. The pumps shall be complete with drive motors, baseplate and other accessories. The constructional features of the pump shall be as follows:
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

1.06.00 1.06.01 1.06.01.01 1.06.01.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 7 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS a). Pump casing may be axially or radially split. The casing shall be of robust construction. Casing drain and vent connections shall be provided. Impeller shall be made in one piece and securely keyed to the shaft. Locking device shall be provided to prevent its loosening during all conditions of operation. Wearing rings shall be of renewable type. Opposed wearing surface shall be of hardened material and shall have a hardness difference of at least 50 BHN. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through bearings and stuffing boxes. The end of the shaft sleeve assembly shall extend through the packing gland. Shaft sleeve shall be securely locked or keyed to the shaft to prevent loosening or rotation. Shaft and shaft sleeves shall be machined and assembled for concentric rotation. The design of the shaft shall take into consideration the critical speed, which shall be at least 20% away from operating speed. Pump bearings shall be of antifriction type. Bearings shall be readily accessible without disturbing the alignment of pump. Packed stuffing boxes shall be of sufficient length to prevent leakage along the shaft and shall be complete with all packing and lantern rings required. Pumps shall be furnished complete with an approved type of flexible coupling. Couplings guards made of expanded metal and bolted to the base plate shall be furnished. The common base plate for pumps and motor shall be in one piece and shall be made of fabricated steel. Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 m3/hr.

b).

c).

d).

e).

f).

g).

h).

i).

j).

k).

1.06.01.03

The power, head and flow characteristics of each pump shall be suitable for parallel operation. The Power characteristics of the pumps shall be of non overloading type. All rotating parts of the pumps shall be statically and dynamically balanced. The motor shall be rated for continuous operation and confirm to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of pump. Design duty point of pump shall match with the average value of maximum and minimum flow rates of the pump in the stable operation zone.

1.06.01.04 1.06.01.05

1.06.01.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 8 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Materials of construction of pump components shall be as stated in data-sheet to this section. Sump Pumps The pumps shall be of wet pit types, vertical shaft and impeller shall be specially designed to pass large solids or unscreened liquids. The construction and material shall be suitable for pumping coal/dust contaminated water with a minimum of maintenance. All bearings of the pump shall be located above the water level. The piping system shall be designed to suit operations of pumps including standby pump. Materials of construction of sump pump components shall be as stated in Data sheet of this section. Piping, Fittings, Valves and Specialties Piping & Fittings (a) Material of construction of piping and fittings shall not be inferior to those given in data sheet of this section. All piping shall be capable of withstanding the maximum pressure in the corresponding line at the relevant temperature. In general pipe sizes 65 mm NB and larger are to be joined by butt welding and pipe work of size 50 mm NB and below by socket welding/screwed connections. Joints at valves or specialities shall be flanged for sizes 65 mm NB or large and screwed for sizes 50 mm NB and below. All galvanised piping shall be joined by screwed connections. Minimum pipe diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall be 32 NB. However, for dry fog DS System, the minimum pipe size shall be 20 NB. End preparation for butt welding shall be done by machine/flame cutting. Socket weld and preparation shall be saw/machine cut. Hangers and supports shall be capable of carrying the sum of all concurrently acting loads. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. All guides, anchors, braces, dampers, expansion joints and structural steel to be attached to the building/structure, trenches etc. shall be provided. . All piping shall be routed on ground on concrete pedestals and at road crossings, these shall be through hume pipes.

1.06.01.07

1.06.02 1.06.02.01

1.06.02.02

1.06.02.03

1.06.03 1.06.03.01

(b)

(c)

(d)

(e)

(f)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 9 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Valves and Specialities (a) Valves & Specialities shall be used to start, stop or regulate the flow. All valves/specialities below 50 mm size in service water/dust suppression/ potable water lines should be plug type of proven make. All valves shall be suitable for most stringent service conditions i.e. flow, temperature and pressure under which they may be required to operate. Gate/sluice valves shall be used for isolation of flow of pipe lines above 50NB and Globe valves shall be used for regulating the flow. Valves shall be provided with back seating bush to facilitate gland renewal during full open operation. All gate and globe valves of size 65 NB and large shall be bolted bonnet, outside screw, rising type with flanged ends. Valves of size 50 NB and smaller shall be with screwed ends. Valves shall be provided with the following as necessary : (1) (2) (3) (g) Hand wheel Position indicator Draining arrangement.

1.06.03.02

(b)

(c)

(d)

(e)

(f)

Material of construction of valves shall not be inferior to those given in data sheet of this section. Globe valves shall be provided with contoured plug to have well controllability. Non-return valves shall be swing check type. These valves will have a permanent arrow inscription on its body to indicate direction of motion of the fluid. All valves shall be provided with hand wheel, chain operated, extension spindle and floor stand wherever required so that they can be easily operated either at a lower or higher elevation as the case may be. Strainer shall be of duplex type designed with 3 way valves so that one filter can be cleaned while the other is in operation. Suitable vent and drain valves shall also be provided. Screen opening area shall be at least four times the pipe cross sectional area. Pressure drop in clean conditions shall not exceed 1.5 MWC at full flow. Bib cocks provided for potable water system shall be made of Copper Alloy / Cast Iron.

(h)

(i)

(j)

(k)

(l)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 10 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Special cleaning, protection and painting Piping & Fittings (a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. For overground exposed steel pipes, one shop and one site coat of red oxide zinc phosphate and two coats of synthetic enamel finishing paints unless specified otherwise shall be applied. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall be applied on the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty bitumastic paint.

1.06.04 1.06.04.01

(b)

(c)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 11 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM 1.0.0 1.1.0 1.2.0 GENERAL Dust Control Miscellaneous systems Dust suppression/ extraction system Service water system, Potable water system, Cooling water system & Sump pumps.

2.0.0 2.1.0 2.1.1 2.1.2 2.1.3

DESIGN REQUIREMENT Dust Suppression Operation Pumps Spray Head (i) (ii) Minimum No. of nozzles per spray head Pressure at inlet (dry fog) 4 (Four) Min. 0.5 kg/cm2 for water Min 5 kg/cm2 for air (iii) Pressure at inlet (Plain water) Minimum 4.5 kg/sq. cm Water sprayed through nozzles. 2x100% for water

2.2.0 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3.0

Plain Water Dust Suppression Pumps Minimum Pressure at inlet of spray nozzles Nozzle spacing for Wagon tippler Nozzles Flow from each nozzle Dry Fog Dust Suppression (i) (ii) Compressor No. of Compressors to be provided Screw Type One working & one Standby, per group One no. of min. 2 cu.m capacity located near compressors & 200 Litres capacity at various location Dry fog type
SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

2x100% electric motor driven 4.5 Kg/sq. cm for wagon tippler 500 mm Fogging type 2.0 Lpm

(iii) air receivers

(iv) Nozzles
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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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CLAUSE NO.

TECHNICAL REQUIREMENTS

2.4.0

Sumps Pumps (i) (ii) (iii) Type Capacity Head 2x100% electric motor driven 50 cub.m/hr minimum with 10% margin 20% margin on computed head Minimum 2 x 2 x 1.8 mts. and 1 No. settling pit for slurry & high/low level switches in drain pit. To nearest plant drain

2.4.1

Drain Pits

2.4.2 2.5.0 2.5.1

Piping Service Water System Water connections (a) (b) (c) Conveyor Galleries and tunnels Junction Towers Crusher House

every 50 m Min. 1 no. at every floor Min. 2 nos. at every floor 32 NB plug valve One in each building of 25 mtr. Length with nozzle

2.5.2 2.5.3

Connection details Hose pipes with hose reel

2.6.0 2.6.1 2.6.2

Potable Water System Pumps Water connections a) (b) (c) (d) (e) Junction Towers Crusher house Control room MCC rooms and toilets Wagon tippler top Minimum one (1) no. at each floor Minimum two (2) no. at each floor Minimum one (1) no. at each floor Minimum one (1) no. each Min. one (1) no. 2 X 100% electric motor driven

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 13 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

3.0.0 3.1.0

CONSTRUCTION REQUIREMENTS Water Supply Pumps for DS/SW/PW/CW Casing Axial or radially split with drain & vent connection One piece, keyed to shaft along with locking device Critical speed atleast 20% away from operating speed At bearings & stuffing boxes. Antifriction type Renewable type (preferable) Below 1500 rpm for capacity more than 10 cub. m/hr. Suitable for parallel operation.

3.1.1

3.1.2

Impeller

3.1.3

Shaft

3.1.4 3.1.5 3.1.6 3.1.7

Shaft sleeves Bearings Wearing rings Pump speed

3.1.8 3.1.9

Head flow characteristics Materials (a) (b) (c) (d) (e) (f) Casing Impeller Impeller Wearing ring Casing Wearing ring Shaft Shaft sleeve

Cast Iron to IS:210, FG 260 Bronze conforming to Gr.I of IS:318 Bronze conforming to Gr.I of IS:318 Bronze conforming to Gr.I of IS:318 Medium carbon steel Stainless steel conforming to AISI-416 hardened. Impregnated teflon

(g) 3.2.0 3.2.1 3.2.2

Gland packing

Sump Pumps Type Duty Wet pit type vertical shaft Capacity to handle unscreened liquid. large solids or

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 14 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

3.2.3

Materials (a) (b) (c) (d) (e) (f) Casing and rotor housing Rotor Shaft Gland Wearing rings Shaft enclosing tube Ni-Cast Iron (350 BHN) Ni-Cast Iron (350 BHN) Medium carbon steel Bronze Stainless steel Carbon steel

3.3.0 3.3.1

Pipings & Fittings Joints (i) Pipe to pipe Pipe size < 50 NB Pipe size > 65 NB (ii) Pipe to valves Pipe size < 50 NB Pipe size > 65 NB Screwed Flanged Plug / Gate / Sluice valves Globe Valve Socket welding/screwed Butt welding

3.3.2 3.3.3 3.3.4

Isolation of flow Regulation of flow Valves (i) (iii) Size > 65 NB Size < 50 NB

Bolted bonnet outside screw rising type. Union bonnet with screwed ends for Globe valve & screwed ends for plug valve

3.3.5

Materials for Pipework (a) For sizes 200 NB and Larger ERW carbon steel pipes to API-5LGr.B/IS:3589 with minimum thickness 6.35 mm ERW carbon steel black pipes to IS:1239 (Part-Heavy class).
SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

(b)

For sizes 150 NB to 65 NB

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PAGE 15 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

(c)

For sizes below 65 NB

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

3.3.6

Materials for Valves & Specialities (a) (i) (ii) (iii) (iv) (v) (vi) (a) Cast Iron Valves Body and bonnet Disc for non- return Seating surfaces and rings Hinge pin for non return valves Stem for gate and globe valves Back seat bush Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2) Body Trim Duplex Strainer Body Strainer Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and syphon) Dial size Accuracy Bourdon Block Movement 150 mm (+/-) 1% of range span AISI 316 SS AISI 316 SS AISI 316 SS MS fabricated Stainless steel type element AISI-316 Gun metal to IS:318, Gr-2. Gun metal to IS:318, Gr-2. 65 NB and above Cast Iron to IS:210, Gr.FG-200 Cast Iron to IS:210, Gr.FG-200 valves 13% chromium steel Stainless steel type AISI-316 13% chromium steel 13% chromium steel

(i) (ii) (b) (i) (ii) (c)

(i) (ii) (iii) (iv) (v)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 16 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

(vi)

Case and Bezel

Die cast Alum. Weather proof case stove enameled block with screwed type inner bezel of ABS plastic and glycerin filled. 2 NO + 2 NC Adjustable throughout the range. IP. 65

(vii) (viii) (ix) (d)

No. of contacts Type of contact Degree of protection Solenoid valve (to be provided with isolating valve) Type Diaphragm Body Pressure Protection Class Flow Switch (to be provided with isolating valves) Body Extension Rod/wire Sleeve and Sleeve pipe Cover Max. working pressure Repeatability No. of contacts Type of contact Protection class Level Switch Type Displacer Wire rope

(i) (ii) (iii) (iv) (v) (e)

2/2 way Diaphragm type pilot operated Molded synthetic rubber Forged brass / SS 0.5 to 10 kg/cm2 IP 65

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (f) (i) (ii) (iii)

Forged steel SS-304 SS-304 Die cast aluminum 10 kg/sq.cm 0.5% 2 NO + 2 NC Adjustable throughout the range. IP 65

Displacer operated magnetic type SS 316 SS 316


TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS PAGE 17 OF 18

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS

(iv)

Spring Housing sleeve pipe Cover No. of Contacts Type of Contact Protection class Level gauges Type

Spring

and SS 316

(iv) (v) (vi) (viii) (g) (i)

Cast Aluminum 2 NO + 2 NC Adjustable throughout the range. IP 65

Float type mechanical gauge with arrow scale (+/-)1% of full scale range

(ii) (iii) (aa) (bb) (cc) (dd) (h)

Accuracy Material of construction Float & Guide wire Elbows Housing Cable fastener Plain water Dust Suppression Nozzles (except for Stockyard DS) Type Material Nozzle housing

316 SS Suitable grade of SS Mild Steel SS 304

(i) (ii) (iii)

Fogging, non-clogging type Stainless Steel To ensure protection of nozzle against damage.

(i) (a) (b) (c)

Y Strainer Body Plug Filter Element SS 304 SS 304 SS 316, 60 mesh

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-09 DUST CONTROL& MISCELLANEOUS SYSTEMS

PAGE 18 OF 18

PART - B SUB-SECTION-IIIA-10 VENTILATION SYSTEM

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

VENTILATION SYSTEMS 1.00.00 1.01.00 GENERAL INTENT OF SPECIFICATION The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete Ventilation & air conditioning systems as specified hereinafter for the smooth and trouble free operation of CHP. 1.01.01 The Contractor shall refer to the other sections enclosed to appraise himself of the work and scope of supply of the other Contractors and shall coordinate his work with the work of other Contractors. GENERAL DESCRIPTION Mechanical Ventilation system The air quantity for mechanical ventilation system shall be estimated based on equipment and solar heat loads and the temperature rise inside the building. Necessary air filters shall be provided to supply only clean air into building. Exhaust air shall be discharged at a suitable height above building. Exhaust fans shall be provided for Toilets, Battery rooms. All underground structure shall be provided with supply air as well as exhaust air fans. 1.02.02 Pressurised Ventilation System The pressurised ventilation system having adequate nos. of supply with washable metallic pre filters, HDPE fine filters, and self closing flap (gravity louver shutter), ducting along with 3 phase AC motor drives, electricals, supporting structures, access / maintenance platforms shall be provided in all MCC/switchgear room areas of coal handling plant to be furnished under this specification. The pressurized ventilation system shall be designed considering 15 air changes per hour to maintain these areas pressurised slightly above atmospheric pressure to prevent ingress of dust from outside. 1.02.03 Air Conditioning System Air conditioning system shall be furnished for control room area of main CHP control building, wagon tippler control room, office room in main CHP control room, office room in wagon tippler control room and in electrical buildings. It shall be designed considering the equipment heat loads, solar heat loads, heat gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and relative humidity within the air conditioned areas. 1.03.00 1.03.01 ENTILATION AND AIRCONDITIONING SYSTEM 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,
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-10 VENTILATION SYSTEM

1.02.00 1.02.01

PAGE 1 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS supporting structures, approach/maintenance platforms, civil and structural works and necessary accessories shall be furnished for ventilating the underground portion of junction towers, underground conveyor tunnels. Exhaust fans shall be provided for Toilets, Battery rooms. The exhaust fans for toilets and battery rooms will be propeller type complete with rain protection coal and bird screen.

1.03.02

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

1.03.03 1.03.03.01

Air Conditioning System 2x100% capacity air conditioning packaged units (PAC) with air cooled condensers shall be provided for Main Control Room , wagon tippler control room, office room of Main Control Room & various MCC Rooms as specified elsewhere in spec. complete with supply and return air ducting. Supply and return air distribution ducting complete with insulation, of resin bonded mineral wool equivalent of density at least 24 Kg/m and thermal conductivity of max. 0.49 mw/cmC conforming to IS:8183 including supporting structures, approach/ maintenance platforms, civil and structural works and necessary accessories shall be provided. Area around centrifugal fans, filters, motor foundation shall be paved to have a clear surrounding. Codes & Standards The design, manufacture, inspection and testing of Ventilation & A/C System shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Ventilation & A/C System shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3588 : Specification for electrical axial flow fans. IS:2312 :Propeller type AC Ventilation fans IS:3963 :Specification for roof-extractor units IS:4894 :Centrifugal Fans

1.03.03.02

1.03.03.03

1.04.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 2 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS IS:655 :Specification for Metal Air Duct ARI:210 :Standard for Unitary air conditioning equipment. ARI:270 :Standard for application, installation and servicing of unitary equipment. IS:8183 :Specification for bonded mineral wool. IS:661 :Thermal insulation for cold surfaces. IS:4671:Expanded polystyrene for thermal insulation purpose. IS:8148 :Packaged Air conditioners.

1.05.00 1.05.01 1.05.02

DESIGN REQUIREMENT Axial Fans Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in the stable operation zone. The speed of the fan shall not exceed 960 rpm for fan with impeller diameter above 450 mm and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed. Impellers shall be axial flow type single piece. Centrifugal Fans The fan units shall be centrifugal type with radial bladed impeller. purpose out door ambient temperature shall be taken as 50 deg.C. For design,

1.05.03 1.05.04 1.05.05 1.05.06 1.05.07

Fans shall be manufactured vibration free in operation and shall be designed to limit noise level within limits specified in Data Sheet. The motor shall be rated for continuous operation and conform to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of fan. All fan mountings shall have adequate arrangement for vibration isolation. The reverse flow through non-working fan shall be prevented by dampers. The dampers shall be made out of 18 SWG MS sheets. Design duty point of the fans shall match with the average value of maximum and minimum flow rate of the fan in the stable operation zone. Filters Metallic Filters Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be 2 m/sec.

1.05.08 1.05.09 1.05.10 1.05.11 1.05.12

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 3 OF 9

CLAUSE NO.

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

1.05.13

1.05.14

High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99% down to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm w.c. Packaged Air-Conditioning Unit PAC units shall be provided as required.

1.05.15

1.05.16

PAC units shall be factory tested and assembled self contained units complete with refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units wherever required shall be insulated with expanded polyethylene conforming to IS:4671. The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled condenser (outdoor air) section. Heavy gauge steel cabinet finished with paint of approved colour, shall be used to house components of PAC. The evaporator and condenser coils shall be arranged for direct expansion cooling and shall be formed of aluminum fins mechanically bonded to seamless copper tubes and electrically tinned. The inter-connecting refrigerant circuits shall comprise of hermetically sealed scroll compressor and motor with all necessary isolation valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries. The condenser coils shall be air cooled by propeller type fans complete with safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pickup from solar sources. Condenser capacity control shall be provided by means of fans and head pressure sensing. The evaporator air blower(s) shall be centrifugal forward curved type belt driven by individual motor(s) and suitable for the external static pressure. The fan assembly shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall be capable of capacity adjustment by pulley changes within +15% of design duty. High efficiency filters shall be provided in the main supply air duct and in the fresh air connection to return air duct. Construction Requirements General construction details of various equipment under Contractors scope shall be as elaborated in subsequent clauses below. Axial Flow Fans Axial flow fans shall be provided as required.

1.05.17

1.05.18

1.05.19

1.05.20

1.05.21

1.06.00 1.06.01

1.06.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 4 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades construction. It shall be finished all over and balanced dynamically. Impeller shall be mounted directly on the motor shaft. Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall be provided with suitable supports. Access door shall be provided in the casing for easy access to motor and impeller. Suitable arrangement for mounting of motor shall be provided. Rain protection cowls will be designed to suit wall exhausters/supply fans for protecting fans/motors from rain. It will be provided with bird screen. Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or M.S. Motor shall be of totally enclosed type complying with the companion electrical specification. Suitable rain/sun shade for motors shall also be provided. Centrifugal Fan Centrifugal fans shall be provided as required.

1.06.03

1.06.04

1.06.05

1.06.06

1.06.07

1.06.08

1.06.09

The casing shall be of welded construction fabricated with heavy gauge material. It shall be rigidly reinforced and supported by structural angles. The seams shall be permanently sealed airtight. Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be provided wherever required. The impeller shall have die formed curved blades fabricated out of MS heavy gauge welded to the rim and back plate to have a non overloading characteristics of the fan. Rim shall be spun to have a smooth contour. If required intermediate stiffening rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically balanced. Fan shaft shall be of EN-8 equivalent. The bearings shall be self-aligning heavy-duty ball or roller bearings. They shall be adequately supported. They shall be easily accessible and lubricated properly from outside. Filters Metallic Filters Metallic cleanable filters shall consist of V-fold galvanised wire mesh inter spaced with a flat layer of galvanised wire mesh. The density of the filter medium shall increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to eliminate the danger of abrasion during handling. Filter medium shall be supported on either side by galvanised expanded metal casing. Filter frame shall be constructed from galvanised sheet of thickness not less than 18 gauge.

1.06.10

1.06.11

1.06.12 1.06.13

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 5 OF 9

CLAUSE NO.

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

1.06.14

1.06.15

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

1.06.16 1.06.17

Package A/C Unit A separate cubicle shall be provided within the overall casing to house the thermostatic controls, which shall be electric/electronic solid state, prewired and tested. The refrigerant system shall be protected by pressure limiting devices, electric and thermal overloads and unloading facilities to provide the required control range tolerances. A low voltage room thermostat or RTD based temperature sensing device shall be provided for wall mounting. The casing shall be fitted with all necessary coil drains and service connections/ entries. PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The units shall be fully packaged and incorporate integral room air sensing control thermostats and manufacturers work fitted safety interlocks. All controls shall be prewired to unit mounted control/power terminal boxes. Ventilation and Air Conditioning system ducting All GI sheet metal ductwork required for ventilation and air conditioning system shall be furnished by the supplier. All ducts and plenums unless otherwise noted shall be constructed out of standard quality galvanised steel sheet. All sheet metal ducts shall be fabricated and installed in conformity to the requirements of IS:655. Steel supports for the ductwork shall be furnished as required. The thickness of ducting steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be 1.25 mm. The flexible connection between fan and ducting shall be on teflon impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m2.

1.06.18

1.06.19 1.06.20

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 6 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET : VENTILATION SYSTEM

1.0.0 1.1.1 1.1.2

GENERAL Mech. Ventilation System Equipment (1) Underground tunnel (2) All other places Centrifugal fans/Axial Fans Axial fans, roof ventilators To provide clean air to all MCC / Switchgear buildings Centrifugal fans/Axial Fans To provide ventilation using fans for specified areas.

1.2.0 1.2.1 1.3.0 1.3.1 1.3.2 1.3.3 1.3.4

Pressurised ventilation system Equipment Air-conditioning system Temperature to be maintained Humidity to be maintained Fresh Air intake Equipment

24 1 deg. C 60 5% relative humidity Minimum 1.5 air changes per hour. 2 x 100 % roof mounted package AC units along with ducting etc. and 2 x 100 % window AC As per weather data given in project synopsis

1.4.0

Outside Ambient Conditions

2.0.0 2.1.0 2.1.1 2.1.2 2.1.3

DESIGN & CONSTRUCTION Axial Fans Capacity Head Speed (a) (b) (c) Impeller dia above 450 mm Impeller dia less than or equal to 450 mm Critical speed Max. 960 rpm Max. 1440 rpm 25% above operating speed. 10% more requirement 20% more requirement of of actual actual

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 7 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS Centrifugal Fans Capacity 10% more requirement 20% more requirement Max. 1500 rpm 50 deg.C. Continuous of actual

2.2.0 2.2.1

2.2.2

Head

than

actual

2.2.3 2.2.4 2.2.5 2.3.0 2.3.1 2.3.2

Speed Outdoor temperature Rating Packaged Air-Conditioning Unit Type Service/application clock. Capacity (i) (ii) TR CFM Continuous, round the

Roof top mounting

2.3.3

Suitable Suitable Hermetically compressor Air cooled type Forward curved centrifugal fan High efficiency filter sealed scroll

2.3.4

Type of compressor

2.3.5 2.3.6

Condenser Fan

2.3.7 2.3.8

Filter Cooling Coil (a) (b) (c) Type Material Fins

Direct Expansion Copper Aluminum mechanically bonded. Copper Expanded polyethylene of density at least 15 kg/cub.m.
SUB-SECTION-IIIA-10 VENTILATION SYSTEM PAGE 8 OF 9

2.3.9 2.3.10

Refrigerant Piping Insulation for PAC parts

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.4.0 2.4.1.

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

2.4.2

HDPE filters (1) (2) (3) Efficiency Max. velocity Testing 90% down to 5 microns 2.5 m/sec. As per BS 2831 / Sqv.

2.4.3

High Efficiency Filter (1) (2) (3) Efficiency Pr. drop across Testing 99% down to 5 microns. 10 mm W.C. As per BS 2831 / Sqv.

2.5.0

Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183 Density Thermal conductivity 24 kg/cub.m 0.49 mw/cm deg.C

2.5.1 2.5.2

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SUB-SECTION-IIIA-10 VENTILATION SYSTEM

PAGE 9 OF 9

PART - B SUB-SECTION-IIIA-11 CHP BUILDING

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CHP BUILDINGS 1.00.00 GENERAL Various buildings in coal handling plant like transfer houses, crusher house, control rooms, MCC rooms complete with all associated civil foundations and other civil, structural and architectural works shall be provided by the Contractor as per the specification. Construction/fabrication/erection and designing aspects of various buildings shall be as per the Civil/Structural specifications. 1.01.00 Codes and Standards The design and construction of CHP Buildings shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The CHP Buildings shall conform to the latest edition of the Indian standards and codes. Other internationally acceptable standards/ codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standards and this specification, the decision in the Employer shall be final and binding. 1.02.00 1.02.01 Design Requirements All CHP buildings shall have sufficient space to accommodate the entire equipment like head end, drive unit and tail end of various conveyors, crushers, hoppers, chutes, control equipments, MCCs, batteries, supports for conveyor bridges, tensioning arrangements, approach/maintenance platforms with ladders, external / internal stairs, handrails, RCC floors, foundations etc. Moreover, ample space shall be provided for maintenance purposes. Outside stairs to transfer points and crusher house shall be open type. However, a weather canopy shall be provided at the top. Mechanical Handling arrangements with adequate monorails etc. shall be furnished for servicing and installation of various housed equipment as described elsewhere. Building floors shall be washed periodically with water for which necessary slope & drains shall be provided from each floor leading to minimum 4 nos. down comers of minimum 273mm OD each building. However for MCC, control buildings and pump houses, minimum 150 mm dia, 4 nos. galvanized MS pipes conforming to IS :1239 shall be provided. The system shall be designed considering water mixed with coal. A drain pit shall be provided near each building to collect water/coal mixture. Overflow from this pit shall be connected to nearest drain. 1 mtr x 1 mtr size dust/debris MS chutes from all the floors to ground floor shall be provided at all buildings/transfer houses and crusher house. The plate thickness shall note be less than 6mm. Various dimensions and relative elevations shown in tender drgs. for various buildings/structures are minimum acceptable to the Employer. However, final dimensions for various buildings/structures and relative elevations shall be decided
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-11 CHP BUILDING PAGE 1 OF 5

1.02.02

1.02.03

1.02.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS based on actual details/maintenance requirements of contractors equipment to meet technical specification requirements without any implication to the Employer. The sizes of these houses shall be approved by the Employer at the stage of detailed employer. Openings in the floors of CHP buildings (i.e. TPs/CH etc.) shall be provided with curb of 100mm high to avoid water falling down to lower floors.

1.02.05

Vertical bracings in transfer points and crusher house shall be provided only along four sides. No bracing system projecting outside the building shall be allowed. Floor at ground shall be provided in all transfer points, crusher house, ground conveyors etc. Level of floor at ground shall be 500 mm above ground/grade level unless noted otherwise. For enclosed ground conveyor 750mm wide plinth protection along with drainage arrangement shall be provided along the conveyor on both sides. Suitable opening at every 50mtr interval shall be provided on either side in a staggered manner for exit / entry of personals. Necessary drains must be provided all along the floors of ground conveyor. The accessories for dust control & miscellaneous system like water pumps etc. shall be housed in separate pump houses. For areas where ground floor is located less than 500 mm above ground level/grade level, outside face of the brickwalls shall be plastered with rich cement-sand mortar (1:4) with neat cement finishing over it for a height of 500 mm above ground level/grade level. Toilet with potable water facilities shall be provided in all MCC, crusher houses and potable water shall also be provided at all junction towers, crusher house, wagon tippler. All associated civil & structural work for the elevator, elevator stairs, platforms at various landings shall be supplied for crusher house where elevator is provided. Necessary facilities for ventilation of tunnels, underground buildings, control/MCC rooms, WT control room and Wagon Tippler shall be provided as specified elsewhere. External fire escape stair case shall be provided for all MCC. External Two (2) Nos. and One (1) No. internal staircase to be provided for crusher house. 5 mtr wide paving beyond the surface drains shall be done around all transfer points, Crusher house for movement of trucks. The approach for trucks should be provided around transfer point, crusher house and upto hoist lifting area. All building shall have the fire protection provisions to meet TAC and IS 3034 regulations.

1.02.06

1.02.07

1.02.08

1.02.09

1.02.10

1.02.11

1.02.12

1.02.13

1.02.14

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-11 CHP BUILDING

PAGE 2 OF 5

CLAUSE NO.

TECHNICAL REQUIREMENTS Construction Requirements Transfer Houses/Junction Tower All overground buildings shall be of steel frame construction. All underground & partially underground structures shall be entirely in RCC. External staircases shall be provided for all transfer points. The transfer houses shall have permanently colour coated steel sheet enclosure with steel framed doors and louvered windows. Crusher House The crusher house shall have permanently colour coated steel sheet enclosure with steel framed doors and louvered windows.

1.03.00 1.03.01 1.03.02 1.03.03 1.03.04 1.03.05

1.04.00

1.05.00 1.05.01

Control / MCC / WT Rooms Control rooms, MCC rooms & WT control room shall be of RCC construction with Brick enclosure. Fire safety wall in/around transformer yards shall be as per detailed engineering. MCC/Switchgear rooms shall be kept pressurised with dust free air by way of pressurized ventilation. Office room and Control Rooms shall be provided with PAC (Packaged Air Conditioning) units. Air-conditioned areas of CHP buildings shall have double glass windows. Roofs/sidewalls shall be provided with insulation to minimise the heat load. All frames of doors and windows shall be of extruded aluminum and shall be capable of isolating the conditioned space. All AC Control rooms & MCC rooms shall have double door entry.

1.05.02

1.05.03

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-11 CHP BUILDING

PAGE 3 OF 5

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET : CHP BUILDING

1.0.0 1.1.0

GENERAL Underground/partially underground Transfer Houses Overground Transfer Houses, Crusher House Control/MCC rooms DESIGN & CONSTRUCTION REQUIREMENT Transfer Houses & Crusher House Space requirement To accommodate all equipments drive units, head/ tail ends of conveyors transfer chutes etc. and to provide adequate space for maintenance. RCC construction with facility to wash the floors. Min. slope of 1:100 for roof and 1:80 for floors in TPs and 1:100 for floors in crusher house shall be provided towards drain pipes. Permanently colour coated cladding Steel construction with minimum 1000 mm width. Steel construction Capacity as per equipment installed From each floor to drain pit suitable to handle coal slurry. Necessary space, platforms / interconnections with the respective buildings, machine room etc. wherever applicable. Only along four sides. RCC Construction

1.2.0

Steel Construction

1.3.0 2.0.0

RCC construction

2.1.0 2.1.1

2.1.2

Roofs & Floors

2.1.3 2.1.4

Walls/Enclosure Stairs

2.1.5 2.1.6 2.1.7

Doors & Windows Monorails Drainage

2.1.8

Elevators

2.1.9

Vertical bracing

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SUB-SECTION-IIIA-11 CHP BUILDING

PAGE 4 OF 5

CLAUSE NO.

TECHNICAL REQUIREMENTS Maintenance platform with handrails. Chequered plate floors Min.1500 mm wide 50 mm thick metallic hardener like ironite floor finish. 500 mm above ground level.

2.1.10

2.1.11

Flooring

2.1.12 2.2.0 2.2.1 2.2.2 2.2.3

Level of ground floor Control/MCC/ WT control Rooms Construction MCC Rooms/ WT control room building Control Rooms

RCC construction with Brick Enclosure Pressurised with dust free air Air conditioned Environment

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SUB-SECTION-IIIA-11 CHP BUILDING

PAGE 5 OF 5

PART - B SUB-SECTION-IIIA-12 VIBRATING SCREENING FEEDER

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

VIBRATING SCREENING FEEDER 1.00.00 GENERAL Vibrating screening feeder shall be provided before each crusher to ensure uniform feeding of coal to the crusher and separation of (-) 20 mm coal from feed to the crusher. 1.01.00 CODE & STANDARD The design, manufacture, inspection and testing of Vibrating screening Feeder shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Vibrating screening Feeder shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the employer shall be final and binding. IS:8723 1.02.00 1.02.01 1.02.02 Dimensions for vibrating conveyors and feeders

DESIGN REQUIREMENT The vibrating screening feeder shall be of mechanical type. The screening feeder shall be capable to segregate the (-) 20 mm size of coal alongwith coal dust, any muck & muddy coal (which is likely to be encountered during rainy season) etc. The segregated material shall be directly fed onto the corresponding belt conveyors/feeders through separate hoppers/chutes provided under each screening feeder. The width of vibrating screening feeder shall match to feed the material uniformly over the entire length of crusher rotor without any deflectors in the feeding chute. The screening area excluding solid deck area shall be minimum 0.75 m2 per 100 tonnes/hr of incoming feed. Inclination of the screening pan shall be so selected so as to ensuing proper flow ability of Coal on the deck without any hindrance. The equipment shall be designed in such a manner that choking does not occur during operation, particularly during rainy season when the coal gets sticky. CONSTRUCTION REQUIREMENT The deck of vibrating screening feeder shall have continuous solid deck section in the impact zone under direct coal fall and remaining deck shall be fitted with perforated deck assembly. The solid deck section shall be provided with replaceable tiscral or eqvt. liner plate of adequate thickness. The perforated deck shall be wear resistant and shall be rigidly fixed with main frame along the length of grizzly deck.

1.02.03

1.02.04

1.03.00 1.03.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIA-12 VIBRATING SCREENING FEEDERS

PAGE 1 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS The vibrating screening feeders shall be mounted on the floor with the help of helical springs made of alloy steel. No rubber/synthetic material for the support shall be acceptable. Vibrator bearings shall be grease lubricated, double spherical roller type suitable for vibrating equipment. The bearings shall be sized for minimum 8,000 hours of operation. Suitable sealing arrangement shall be provided between the vibrating structure and chute work to avoid dust nuisance in the surrounding area. Proper arrangement to avoid dust ingress into lubricant of eccentric shafts shall be provided. Necessary arrangements shall be provided for maintaining / replacing the complete vibrator assembly. Marker plate to indicate stroke length and stroke angle shall be mounted. In case of V- belt drive, suitable arrangement like taper bush or dobicon coupling shall be provided, to avoid loosening of sheave mounted on eccentric shaft. Dust hood shall be provided over the deck of screening feeder to avoid dust nuisance.

1.03.02

1.03.03

1.03.04

1.03.05

1.03.06

1.03.07 1.03.08

1.03.09

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-12 VIBRATING SCREENING FEEDERS

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET : VIBRATING SCREENING FEEDER

1.0.0 1.1.0

GENERAL Functional Requirement Uniform feeding of (+) 20 mm coal to crushers.

2.0.0 2.1.0 2.2.0

DESIGN & CONSTRUCTION REQUIREMENT Type Inclination Mechanical vibrator Suitably selected to ensure proper flow ability of Coal without any hinderance.

2.3.0

Pan Size (a) (b) Screen area Pan width Min. 0.75 sq.m per 100 TPH feed To match with crusher rotor length without deflector plates Suitable to pass (-) 20 mm coal.

2.4.0 2.5.0

Performance size on deck Liners on solid deck Type, Material Thickness

Replaceable, Tiscral or eqvt. 16 mm minimum.

2.6.0

Perforated Deck Assembly Material Construction TISCRAL or equivalent Perforated deck plate Helical springs only

2.7.0 2.8.0

Support Bearings (a) Type

Double spherical roller suitable for vibrating screens. Grease 8,000 hours Min.

(b) (c)

Lubrication Life

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-12 VIBRATING SCREENING FEEDERS

PAGE 3 OF 3

PART - B SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

RING GRANULATOR AND VMS


1.00.00 GENERAL Ring granulator type crusher shall be provided for sizing the input coal to (-) 20 mm size. Crusher shall be supplied complete with accessories and subsystems. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Coal Crushers shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Coal Crushers shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 1.02.00 1.02.01 DESIGN REQUIREMENT The crusher shall be of ring granulator type and shall be designed based on following clauses and the data sheet enclosed. The crusher design should be such that the crushing action is accompanied by the minimum of attrition. Uniform crushing impact shall be assured. Maximum crushing efficiency shall be obtained, i.e., thermo dynamically, the ratio of surface energy produced to the kinetic energy expended should be maximum. Accordingly, the number of central discs along the rotor shaft shall be maximum with minimum spacing in between. The crusher shall be capable of delivering the normal rated output even when handling damp sticky coal having maximum moisture content. No clogging or building up of material on the crushing element shall develop. Temperature sensing devices shall be installed on both bearings of each of the crusher to trip the crusher incase temperature goes beyond limit. CONSTRUCTION REQUIREMENT The gap between cage bars/cage screen and the hammers shall be adjustable to compensate for the normal wear and tear and the mechanism shall be made simpler for easy operation and maintenance, having separate cage actuating shaft, gear train and suitable hinge connection.

1.02.02

1.02.03 1.02.04

1.02.05

1.02.06

1.03.00 1.03.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS

PAGE 1 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS The drive chain equipment for crusher shall consist of drive motors scoop type fluid couplings and other couplings. The crushers with its drive chain equipments shall be mounted on a base plate with necessary accessories, e.g., anchor bolts, coupling guards etc. The specification of the fluid coupling shall be as discussed elsewhere. Gear box shall not be used in the drive chain of crushers. The entire inside surface of crusher coming in contact with coal shall be provided with abrasion resistant steel liners. The plummer block shall be of Split Type design and shall be fixed with minimum four numbers of high tensile steel bolt studs of adequate size complete with adequate locking device and locating arrangement. In addition, the jacking screw shall be provided for easy lifting of top part of the plummer block. The same shall be of solid base with flat machined bottom surface all around having maximum contact on the foundation plate. Additional support shall be provided to plummer block across the longitudinal axis of crusher rotor to take care of misalignment against certain jerk, regular vibration etc., with simple readjustment facilities. Further, plummer blocks shall be provided with provisions for installing vibration monitoring equipment. Necessary locking arrangements shall be provided for suspension bars at both the ends of rotor assembly to arrest any relative movement of the same. In addition, the design shall be such that these locking arrangements do not undergo any damage during normal operation as well as under hammer replacement operation. Two suspension bars shall be provided in each row to facilitate replacement of broken hammers without requiring withdrawal of other hammers. The general arrangement of crusher and the drive equipment shall permit atleast 50% extraction of suspension bars towards the drive end also, besides full extraction towards non-drive end. For safety, necessary tramp iron pocket of sturdy design with adequate cover shall be provided inside the crusher. The bottom of tramp iron pockets shall be of grizzly or screen type. Maximum accessibility shall be provided for routine inspection and replacement of parts. For these purposes, the doors shall be of hinge connection with effective dust sealing arrangement. Hydraulically operated top cover of crushers shall be provided for quick inspection and replacement of hammers. The material for major components of crusher shall not be inferior to the quality and standards as mentioned in data sheet. VIBRATION MONITORING SYSTEM FOR COAL CRUSHER Vibration monitoring system should be offered for crushers as indicative below :

1.03.02

1.03.03

1.03.04

1.03.05

1.03.06

1.03.07

1.03.08

1.03.09

1.03.10

1.04.00 1.04.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS

PAGE 2 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

Sl. No 1.

Equipment

Type

No.

* No. of Equipment location type per equip. 2 one at DE one at NDE

bearing

Coal Crusher

Radial

ring 4

As per manufacturer's design

Vibration shall be measured at each location in Horizontal as well as vertical direction. 1.04.02 Specification of the Vibration Monitoring System a) Number & vibration type of One (1), Microprocessor based, monitoring system able to distinguish between high frequency vibration caused by bearing trouble and low frequency vibration caused by imbalance. 16 (Rack mounted in cabinet) a) Velocity pick-up or a peizoelectric accelerometer. Type shall be decided during detail engineering based on the details of equipment to be monitored. Light weight stud mounting. Frequency response 1 Hz -10 kHz.

b) c)

Number of channels Transducer

b) c) d) Connecting cable

Low noise fire proof coaxial cable to be laid in flexible conduit. Dual channel monitor for each location alongwith : a) Buffered signal output and software for vibration analysis through CHP control desk HMI. Recorder signal output

e)

Monitors (to be located in CHP control room)

b) f) g) h) i) Display Alarm Trip Test

Analogue and digital 0-100% full scale adjustable. 0-100% full scale adjustable. Functional checking from front inhibiting alarm & trip

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS

PAGE 3 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

j)

Relays

0.25 A at 220 Volts DC or 5 Amp at 240V AC. Independent potential free contacts for alarm & trip purpose. Individual 4-20 mA DC analogue output. 240 V 10% AC, 50 Hz + 3%, -5%

k) l)

Signal Conditioner Power Supply

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS

PAGE 4 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : CRUSHER 1.0.0 1.1.0 1.2.0 1.2.1 GENERAL Type Input Coal Parameters Extent of oversized lumps (occasional) in feed coal (a) (b) 1.3.0 Maximum percentage Maximum lump size 1 to 2% 400 mm Through vibrating screening feeder (However, the crusher shall be designed/sized considering zero passage of coal through screen). Ring granulator As specified elsewhere.

Coal Feeding Arrangement

2.0.0 2.1.0 2.2.0

DESIGN AND CONSTRUCTION Number of rows of hammers Hammer profile 4 rows placed at 90deg Toothed and plain alternately or only toothed Not to exceed 40 Kg. passing through Max. of Two (2) number

2.3.0 2.4.0

Weight of each ring hammer No. of suspension bars each row of ring hammers

2.5.0

No. of holes in each segment of central and end Max. of Three (3) number discs for suspension bars (for each row of hammers) Drive arrangement Motor rating at 50oC Refer technical specification elsewhere

2.6.0 2.6.1

2.6.2

Fluid coupling Type Scoop tube type

2.7.0 2.7.1

Rotor Balancing Type of balancing reqd.


TECHNICAL SPECIFICATIONS SECTION-VI PART-B

Both static and dynamic


SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS PAGE 5 OF 7

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS

2.7.2

Grade of balancing

Q-16 as per VDI-2060 1966 (However, for purpose of calculating the unbalanced force for the design of machine supporting structure, balance grade as given in the relevant section for foundation design shall be followed).

2.8.0 2.8.1 2.8.2

Plummer Block Type of plummer block Type of sealing Split type Labyrinth, arrangement Spherical roller Manual through grease gun OR with recommended grade of oil in which case the plummer block shall be designed with oil filling, oil draining and visual oil checking facilities dust tight

2.8.3 2.8.4

Type of bearings Lubrication

2.9.0

Tramp iron rejection

Required for unbreakable material facility Desirable Hydraulically operated

2.10.0 2.11.0 3.0.0 3.1.0

Output size adjustment facility Top cover of crushers MATERIAL OF CONSTRUCTION Ring Hammers

Manganese steel to IS - 276 Gr. III or made of low alloy (sillico manganese) steel in forged condition as per ASTM A 322 grade 9260 ASTM-A668, Class E / C45(IS 2004) / E8D, BS 970/1955 ASTM-A322, Grade AISI 4140 / EN-24, Bright bar
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS PAGE 6 OF 7

3.2.0

Rotor Shaft

3.3.0

Suspension bars

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS

3.4.0 3.5.0 3.6.0 3.7.0

Cage bars/cage screens and side screen plates Rotor Discs Breaker plate Liners (a) Material

Manganese Steel (IS:276) / ASTM-A108, AISI 1045 Manganese steel IS-276 Gr. III min. 40mm thick

Material composition shall be as that of breaker plate above 20 mm minimum.

(b)

Thickness

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-13 RING GRANULATOR AND VMS

PAGE 7 OF 7

PART - B SUB-SECTION-IIIA-14 IN-LINE MAGNETIC SEPARATOR AND SUSPENDED MAGNET

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

IN-LINE MAGNETIC SEPARATOR AND SUSPENDED MAGNET


1.00.00 GENERAL Inline Magnetic Separators shall be provided for continuous and automatic extraction and discharge of tramp magnetic pieces from coal being discharged from conveyors as specified. The sets shall be complete in all respects with drives, magnets, inline belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control panels etc. Suspended Magnetic Separator shall be provided for picking up tramp magnetic pieces buried under coal from moving coal over Conveyor as specified. 1.01.00 CODES & STANDARD The design, manufacture, inspection and testing of In line Magnetic Separators shall comply with all the currently applicable statutes, regulations and safety codes in The Magnetic Separators shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 1.02.00 1.02.01 1.02.02 DESIGN REQUIREMENT Inline Magnetic Separator / Suspended Magnet Magnet core material shall be pure annealed iron or equivalent high permeability magnetic material. The coil shall be of aluminum wire with class H insulation, to limit the absolute temperature of the winding to 140 deg. centigrade. The oil used for cooling the ILMS and SM shall be silicon based. The Force Index i.e. the product of flux density in gauss and rate of change of flux density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000 (gauss x gauss/inch) minimum in hot condition for mounting height of 450mm in the conveyors carrying uncrushed coal & 400 mm in the conveyors carrying crushed coal. However, the strength of the magnet shall not be less than 1000 gauss in hot running condition at distance of 450mm in the conveyors carrying uncrushed coal & 400 mm in the conveyors carrying crushed coal. The minimum strength of the magnet shall be 1000 gauss at the specified mounting height at the centre of Belt width. Contractor shall select magnet width to suit above. Mounting height of 450mm in the conveyors carrying uncrushed coal & 400 mm in the conveyors carrying crushed coal shall be taken between top of conveyor belt or bottom of falling material trajectory and the surface of magnetic separator belt. Characteristic curve of magnet with the value of flux density varying between 50 mm to face of conveyor belt shall be provided. The cross section of magnet shall be suitably designed to provide sufficient area for magnetising the coil effectively covering full cross section of the discharge material. The magnetic separator shall be located such that it picks-up tramp iron from coal trajectory after it has been discharged from head pulley.
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-14 IN-LINE MAGNETIC SEPERATOR AND SUSPENDED MAGNET PAGE 1 OF 4

1.02.03

CLAUSE NO.

TECHNICAL REQUIREMENTS The tramp magnetic pieces buried under coal picked up by the magnetic separator shall be discharged suitably to ensure that it falls into the tramp iron chute, which shall be provided upto ground level. All conveyors with magnetic separator at head end shall have non-magnetic SS pulleys. Head pulleys of all conveyors with in line magnetic separator at head end shall be provided with SS shell and end disc. However, hub and shaft shall be of same materials as in other pulleys. (EN-8 or equivalent). The motor and the gear reduction unit for driving the in-line belt shall be adequately sized with minimum 20% margin to avoid any over loading during operation. Suitable zero speed switch shall be provided. No Chain/belt drives shall be accepted. The belt shall be designed to withstand high temperature at the bottom of the magnet and any serious damage due to the impact of the sharp edges of the tramp iron. The belt shall be provided with rubber cleats spaced suitably. The belt shall be of fire resistant grade. For other details of belt, refer belt specification as specified else where. Side rollers shall be provided to keep the belt aligned. The idlers and the pulleys supporting the belt shall be manufactured to the best engineering practices and shall conform to relevant Indian Standards. For details of idlers & pulleys, refer specification as specified else where. CONSTRUCTION REQUIREMENT In-line Magnetic separator / Suspended Magnet The magnetic separator units shall be supported by suitable structural member from the top by taking support from the operating floor beams with turn buckle arrangement to facilitate the necessary adjustments during operation. Further, electric Hoists operated cross travel arrangement shall be provided to move the magnetic separator away to facilitate maintenance of the conveyor discharge pulley/Belt. ON/OFF control push buttons with indicating lamps shall be provided at the local station. The materials of chutes and hoppers associated with magnetic separators above the drive floor shall be SS-304 in the magnetic zone. Other chutes shall be of 1 mtr. sq. dimension and shall be made of MS. chutes shall have poking doors at all floors to clear jammed material. Suitable arrangements shall be provided in the magnet for keeping the coil of the magnet dry from atmospheric condensation when the magnetic separator is not in use. Protection against high oil temperature in magnet shall be provided.

1.02.04

1.02.05

1.02.06

1.02.07

1.03.00 1.03.01 1.03.02

1.03.03

1.03.04

1.03.05

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-14 IN-LINE MAGNETIC SEPERATOR AND SUSPENDED MAGNET

PAGE 2 OF 4

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : ILMS/SM 1.0.0 1.1.0 GENERAL Type In line or suspended magnet type as specified.

2.0.0 2.1.0 2.1.1

DESIGN & CONSTRUCTION In-line Magnetic Separator / Suspended Magnet (a) Location of ILMS (b) Location of SM Over discharge pulley. Over Conveyor tender drawing) (as per

2.1.2 2.1.3

Force index (As defined earlier) Minimum 100,000 Strength of magnet at the specified mounting 1000 gauss. height Mounting height Mounting height of In Line Magnetic Separator and Suspended Magnet shall be 450mm in the conveyors carrying uncrushed coal & 400 mm in the conveyors carrying crushed coal (between top of conveyor belt & surface of magnetic separator)

2.1.4

2.1.5

Magnetic Separator Belt (i) Drive Unit Adequately sized with 20% margin. Suitable to withstand high temp. & impact of tramp iron. (FR Grade) Into Tramp iron chute.

(ii)

Belting

(iii) 2.2.0

Discharge

Tramp Iron Items (i) (ii) MS cube of 20 mm size Brake shoe of Railway Wagon (Cast Iron 15 Kg.)
SUB-SECTION-IIIA-14 IN-LINE MAGNETIC SEPERATOR AND SUSPENDED MAGNET

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 3 OF 4

CLAUSE NO.

TECHNICAL REQUIREMENTS (iii) (iv) MS plate of 250 x 250 x 100 mm size. Shovel Teeth and spikes. Carbon Steel Typical MS round bar of 50 Kg with L/D ratio not exceeding 5.

Material Size (v)

2.3.0

Control Inline Magnetic Separator / Suspended Magnet Local and remote Silicon Rectifier units Nearby control/MCC room

2.4.0 2.5.0 2.6.0

Electric Supply 415V, 3 phase, 50 Hz input Location of silicon rectifier unit Handling Arrangement for inline Magnetic separator/Suspended magnet (a) (b) Height adjustment Cross-travel

With turn buckle arrangement Electric Hoist operated cross travel facility.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-14 IN-LINE MAGNETIC SEPERATOR AND SUSPENDED MAGNET

PAGE 4 OF 4

PART - B SUB-SECTION-IIIA-15 METAL DETECTOR

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

METAL DETECTOR
1.00.00 GENERAL Metal detectors shall be provided at specified location to detect metallic objects in the coal stream. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Metal Detectors shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Metal Detectors shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 1.02.00 1.02.01 DESIGN REQUIREMENT Metal detectors shall have high reliability with enough sensitivity to detect 25mm aluminum sphere below the burden of coal in case of synthetic belting. However, for steel cord belting the sensitivity shall be 35mm. It shall also detect other metals, like brass, copper, stainless steel, manganese steel, bars, scraps etc. The equipment shall have provision for automatic static calibration with adjustable sensitivity. Metal detectors shall be completely solid state using latest state of art technology. It shall be suitable for 50C ambient and RH of 100%. The search sensor shall be protected from rain and direct sunlight by means of a non metallic covering other than wood. Control unit shall have adjustable controls for sensitivity, ON/OFF push buttons, resettable operation counter, audio-visual alarms local remote selector switch and all other necessary controls for trouble free operation of metal detector. It shall be suitable for mounting on wall, column, structure etc. with IP-65 Degree of protection. It shall be constructed from FRP of thickness not less than 2mm. The metal detectors shall also have the following features : (a.) The coils shall be protected against being struck by an oversized material/coal. The coils should have adjustment for magnetite/iron in incoming coal. It should ignore magnetite/iron and shall distinguish between metal pieces and magnetite/iron. In order to counteract interference from external sources such as motors, lightning and radio-transmitters, and to nullify the effect of climate changes/aging, dual receiver coils are to be used.

1.02.02

1.02.03

1.02.04

(b.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-15 METAL DETECTOR

PAGE 1 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS (c.) In order to allow passing of steel cord belt and metal belt fasteners without giving alarm and at the same time detecting tramps, suitable arrangements shall be provided. In case a few non-magnetic idlers or non magnetic deck plates are required, the Contractor shall provide these. However, these shall be metallic. Wood is not to be used. LED display of COAST COUNT to indicate the number of pieces of tramp iron detected since last reset shall be provided so that the operator is alerted for the pieces of tramps, if any, between tramp marker and coil before restoring conveyor. TOTAL COUNT, which is not resettable, shall also be provided on the same LED display on demand. The location of tramp metal pieces shall be indicated by sand bag marker.

(d.)

(e.)

(f.)

(g.) 1.03.00 1.03.01

CONSTRUCTION REQURIEMENT Fiber glass enclosure (with IP 65 degree of protection) shall be provided for all type of coils. Sand bag markers shall be provided. Local control panel shall be provided with IP:65 degree of protection.

1.03.02 1.03.03

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-15 METAL DETECTOR

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : METAL DETECTOR 1.0.0 1.1.0 2.0.0 2.1.0 GENERAL Type DESIGN & CONSTRUCTION Sensitivity 25 mm aluminum sphere below coal for synthetic belting. 35mm Aluminum sphere below coal for steel cord belting. Coil type

2.2.0 2.3.0 2.4.0

Enclosure Control Calibration

Fiber glass Through local control panel. Provision for automatic static calibration with adjustable sensitivity.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-15 METAL DETECTOR

PAGE 3 OF 3

PART - B SUB-SECTION-IIIA-16 COAL SAMPLING UNIT

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS COAL SAMPLING UNIT

1.00.00

GENERAL a) Coal Sampling Unit shall be complete with necessary samplers, crushers, flap valves, chutes, hoppers, belt feeders and sample collectors etc. to give samples from any of the two streams running at guaranteed capacity. Bidder shall source coal sampling system from a manufacturer / supplier who has engineered and supplied two (2) numbers of coal sampling systems for sampling coal / other bulk mineral from conveyor of 1200 MTPH and above and working successfully for two years as on date of bid opening.

b)

1.01.00

CODES AND STANDARDS The design, manufacture, inspection and testing of Coal Sampling Unit shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Coal Sampling Unit shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. ASTM-D-2234 :Standard Methods for collection of a Gross Sample of Coal. ASTM-D-2013 :Standard Method of Preparing Coal Samples for Analysis.

1.02.00 1.02.01 1.02.02

DESIGN REQUIREMENT Coal sampling unit shall be automatic & provided at place specified elsewhere. The coal sampling units suitable to give Samples conforming to ASTM-D-2234 shall be selected by the Contractor for taking samples from any of the two streams running at guaranteed capacity. The different Equipment selected for coal sampling unit shall be such that there shall be no loss of fines and moisture from the samples. The capacity, make and model of all equipments of coal sampling unit shall be subject to approval of Project Manager. The normal input feed size shall be considered as (-) 250 mm for coal sampling unit before coal crusher. However occasionally (-) 400 mm lumps may also arrive. Coal lump size after crusher (as fired coal) shall be (-) 20mm. However occasionally (-) 50 mm lumps may also arrive in as fired coal. Primary samplers (separate for each conveyor) shall be rugged, able to withstand severe shock loads and operate trouble free. Belt feeders shall be provided for entire sampling path upto sample collector. The feeders shall meter the flow accurately, produce a non-plugging condition and resist sticky and wet coal.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-16 COAL SAMPLING UNIT PAGE 1 OF 3

1.02.03

1.02.04

1.02.05

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

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

1.02.06

Sample crushers (make subject to Employers approval) shall be provided for reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4 mesh size. Single stage crushing shall be provided. There should be no re-circulation of fines in the crushers. Lot size shall be equivalent coal quantity handled in 8 hours operation assuming average conveyor loading at 75% of rated conveyor capacity. However sampling system shall also be suitable for taking one gross sample for each lot of 3500 Te coal (approx. equal to one rake load). CONSTRUCTION REQUIREMENT The traversing mechanism and all electric parts shall have dust tight protection. Belt feeders shall be positively self cleaning and have dust tight construction. It shall be provided with flanged belt, rubber lagged head pulleys and inspection doors. No chain/belt drives shall be accepted. The crushers base should be built of reinforced concrete and be sufficiently large in mass. The primary / secondary samplers shall be of dust tight construction and self contained type. The sample chutes shall have minimum valley angle of 60 degrees to horizontal and shall be of stainless steel plates. The chutes shall be suitable to handle wet sticky coal as specified elsewhere. The welding of chutes shall be done externally only. The inside surface of the material near welds shall be smooth. Radius at corners not less than 1" shall be provided in chutework. All solid connected members shall be by means of bolting flanges with atleast 6 mm thick standard grade neoprene gasket material between the metal flanges. No control gates to regulate the flow of material shall be incorporated in the chute work. Bias connections shall be provided at suitable locations. The materials rejected from samplers shall be returned to main conveyor stream. Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The bins shall be provided with air tight connection.

1.02.07

1.03.00 1.03.01 1.03.02

1.03.03

1.03.04

1.03.05

1.03.06

1.03.07

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-16 COAL SAMPLING UNIT

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS DATA SHEET : COAL SAMPLING UNIT

1.0.0 1.1.0 2.0.0 2.1.0 2.2.0 2.3.0 3.0.0 3.3.1 3.3.2

GENERAL Type DESIGN & CONSTRUCTION Codes & Standard Uncrushed feed coal size Crushed feed coal size CHUTES Min. angle Cross section 60 deg Square/rectangular with rounded corners. Bolted flanges with 6 mm thick standard grade neoprene gasket. ASTM D-2234 (-) 250 mm (-) 20 mm Automatic

3.3.3

Joints

4.0.0 4.4.1 4.4.2 4.4.3 4.4.3 5.0.0 5.5.1 5.5.2 5.5.3

CRUSHER Uncrushed (as received) feed coal size Crushed (as fired) feed coal size Output size Stages of size reduction BELT FEEDER Belt Pulleys Drive Flanged type, FR grade Rubber lagged head pulley Electric Motor (-) 250 mm (-) 20 mm ASTM D-2234 Single stage crushing

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-16 COAL SAMPLING UNIT

PAGE 3 OF 3

PART - B SUB-SECTION-IIIA-17 ELEVATOR

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

ELEVATOR 1.00.00 GENERAL This specification is intended to cover design, engineering, supply, erection, testing and commissioning of the complete Rack & Pinion type Elevators as specified hereinafter complete in all respects and adequate for safe, efficient and trouble free operation of the elevator. 1.01.00 CODES AND STANDARD The design, manufacture, inspection and testing of Elevator shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Elevator shall conform to the latest edition of standards and codes. Other internationally acceptable standards/ codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 1.02.00 1.02.01 1.02.02 DESIGN AND CONSTRUCTION REQUIREMENTS GENERAL This section covers the design, engineering, fabrication, installation, commissioning and testing of the rack and pinion type vertical lift elevator including required enclosures, hoist, mast and guide rail, cab drive unit machinery buffers, power cable, control cable, mechanical and electrical equipment. The design of the elevator shall be in such a way that the elevator operation will be safe at all times. Elevator shall be located as indicated in the relevant tender drawings and shall be capable of operating from the ground floor to the top interior platform with intermediate stops at all interior platforms. All mechanical and electrical operating devices and Trailing cable shall be designed for outdoor operation with dusty and high humidity conditions and shall operate equally well in any ambient temperature as per project synopsis. Additionally, all mechanical and electrical components of the elevator shall be designed to withstand a temperature of 50C ambient. ENCLOSURES A three-sided enclosure with one access door shall be provided for ground landing. At each platform landing above ground level, a one sided enclosure with access door shall be provided. Enclosures shall be fabricated from tubular steel and/or other structural shapes expanded metal or wire mesh of suitable height and primer coated with one coat of the manufacturers standard primer and finish paint. The ground landing shall be provided at a suitable height above the foundation slab to ensure a safety space underneath the cage. The space under the landing shall be surrounded by foundation enclosure. The staircase shall be provided for access to the cage. Enclosure access doors shall be electrically and mechanically interlocked
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-17 ELEVATOR PAGE 1 OF 7

1.02.03

1.02.04

1.02.05

CLAUSE NO.

TECHNICAL REQUIREMENTS so that they remain closed and locked except when the cab is at a landing. Doors shall be bi-parting and swinging type. Base of the three-sided enclosure shall be securely anchored to the ground level floor slab using expansion type anchors.

1.02.06

Mast Mast shall be provided in sections of suitable length, consisting of tubular sections and/or structural shapes welded together to form a framework to which the rack is bolted. Mast shall be securely anchored to the building structure.

1.02.07 1.02.08

Cab Cab frame shall be fabricated from tubular steel and/or other structural shapes enclosed with expanded metal or wire mesh. Cab floor shall be of 6 mm thick Aluminum chequered plate or approved equivalent. Cab shall be attached to a framed structure and form an integral part with the drive mechanism located atop the cab. Framed structure shall include guide rollers and safety hooks to ensure positive engagement of the rack and pinion to prevent cab disengagement in case of roller failure. Cab roof shall be provided with an escape hatch electrically interlocked with the hoist control system. Tubular steel handrail shall enclose the cab roof for maintenance operations. Cab door and landing level enclosure doors shall be electrically and mechanically interlocked to prevent the cab from being operated unless the cab door and landing level enclosure doors are fully closed and to prevent the doors from being opened while the cab is in motion. One cabin fan and two recessed fluorescent lamps along with the fittings to be provided with one no. emergency light with battery & battery charger. Drive Unit & Safety Device Drive unit located on the cab shall be complete with AC squirrel cage induction motor, reduction gear, drive pinion and an over-speed governor. Drive unit shall incorporate an electric disc brake and an external manual brake release. The brake on the electric motor will be self adjusting type. In case of the power failure, the brake will be automatically applied & will stop the cab. A hand lever, which can be operated from the cage, is to be provided to enable the occupants to ease the brake and lower the cage to the bottom level. Motor shall be connected to a reduction gear, which drives the pinion. An over-speed governor must be incorporated to protect the cab against over speed during the cab downward motion. At a predetermined speed higher than normal, the brake, mechanism shall be actuated and stop the downward motion of the cab
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-17 ELEVATOR PAGE 2 OF 7

1.02.09

1.02.10

1.02.11

1.02.12

1.02.13

1.03.00 1.03.01

1.03.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS gradually. The brake should remain locked on following this action and has to be manually reset before normal elevator operation can be resumed.

1.03.03

A remote control shall be provided for testing the safety device. The Contractor shall ensure that no individual is in cab during the test. The drive system shall be designed so that it will be capable to operate smoothly without any tendency to rock or judder with all vertical, horizontal forces as well as the moments through the rack. Suitable arrangement shall be provided to bring the cage safely to the ground by gravity in the event of power failure. Buffers Sufficient no. of buffers of spring loaded/hydraulic type shall be fitted below the cab. The buffer shall be capable of stopping the cab without permanent damage or deformation to themselves or any other part of the equipment. The no. of buffers shall be fixed as to ensure proper sharing of impact loads by all of them.

1.03.04

1.03.05

1.04.00

1.05.00

Power Supply Two in comers (one from Bus-A and one from Bus-B of the MCC) for the power supply to each elevator shall be provided with cable key inter to check.

1.06.00

Power and Control Cabinets All electrical components furnished with the elevator shall be completely wired, energised and checked. All electrical control devices shall be in enclosures. Equipment furnished shall also include the following : (a.) Momentary contact push button for raise/lower control. (b.) Reversing combination motor starter with a three phase thermal overload relay for motor protection. However, the control circuit in the elevator will have miniature circuit breakers. (c.) Electric and mechanical interlocks on cab access door and landing level enclosure doors.

(d.) An ultimate three phase over travel limit switch which cuts off power and control supply in case of over travel. The switch can also be manually turned to off position. (e.) Safety device as mentioned elsewhere in this specification. (f.) An alarm push button shall be provided in the cage. transferred to the auxiliary panel at elevator base. Alarm signal will be

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-17 ELEVATOR

PAGE 3 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS The auxiliary panel at the base will have battery and battery charger for the alarm horn. Potential free contracts for remote alarm shall also be provided. (g.) Reverse phase relay connected to prevent operation of the cab with improper phase rotation or failure in any phase in the power supply. (h.) The cable shall be supported by brackets on the cage and guide rails. A cable trolley will keep it in tension and will be guided on the same rail as the cage. The trailing cable shall run through cable guides. (i.) One auxiliary panel shall be furnished and mounted on the ground level enclosure. Panel shall be in enclosure equipped with a main ON-OFF switch, main Contractor, relays, control transformer and MCBs, terminal blocks, and all other accessories required for normal operation of the elevator. One main control panel shall be furnished and mounted on the top of cab. Panel shall be in enclosure equipped with necessary equipment like rectifier, battery, battery charger, contactors, breakers, control transformer and MCBs, thermal overload relays and all other equipment and accessories required for normal operation of the elevator. Cab shall be controlled by a semiautomatic control system with push buttons for UP Down and Stop next landing. The cab shall be controlled from inside and shall have painted placard located above the door. Cab shall be furnished with emergency alarm push button, limit switches, and all other necessary control devices required to ensure safe and continuous cab operation, One trailing cable shall connect the cab main control panel to the auxiliary panel at ground level to supply the cab with all power requirements. An extra core of equal size shall be provided for earthing of cab. Cable guides shall be installed every 6 meters to avoid entanglement of this cable. Each landing assembly shall include a limit switch and push button control station installed and wired to a landing junction box.

(j.)

(k.)

(l.)

(m.) All enclosures containing electrical, devices shall be provided with 240 Volts, single phase space heaters with adjustable thermostat control. (n.) Cab shall be equipped with a 220 Volts, 20W fluorescent lights, fan, 5A, 220V, 3 pin receptacle, emergency light, battery & battery charger. (o.) Control cabinets shall be sheet steel enclosed dust, weather and vermin proof. Sheet steel used shall be cold rolled and at least 2.0 mm thick. Degree of protection of control cabinet shall be as per relevant electrical section. Control cabinet shall be provided with hinged doors (s) with pad locking arrangements. All doors, removable covers and plates shall be gasketted all round with neoprene gaskets. (p.) Each motor to be controlled from the control cabinet shall be provided with 3pole isolating switch. HRC fuses, contactors shall be of AC4 duty class with thermal overload relays with single phase preventer. The isolating switch and contactor shall be rated at least 20% more than the connected motor full load
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-17 ELEVATOR PAGE 4 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS current. The controller and resistor for motor shall confirm to relevant IS and shall be continuously rated for 150% full load current of the motor. (q.) All fuses shall be of the HRC cartridge type mounted on plug in type of fuse base having a prospective current rating of not less than 80 kA. (r.) All push buttons shall have 2NO and 2NC self reset contacts.

1.07.00

Electric Motor Elevator drive motor shall be squirrel-cage induction type designed and manufactured to conform to the requirements of this specification. Motor shall be designed for operation at the required speed, 415Volts, 3 phase, 50 hertz, and shall be suitable for full voltage starting, frequent starting S3 duty class as per IS:4722 with CDF of 25% and maximum number of starts 120/hour at 50C ambient temperature. Motor nameplate kW ratings shall not exceed when the equipment is operating within the limits of the maximum load requirements. Motor shall have class F nonhygroscopic insulation with temp. rise limited to Class B (IS:325), Motor shall be totally enclosed and furnished with cast iron or Al alloy frame, brackets, gaskets conduit box & fan cover. Motor shall be furnished with grease pre lubricated, double-shielded, anti-friction bearing having life rating of not less than 42,500 hours under coupled service requirements. All exposed metal surfaces shall be protected with a polyester paint or coating which is moisture & corrosion resistant. Motor shall be provided with internal 220 Volt AC single-phase space heaters or an alternate heating system to prevent condensation within the motor during extended periods of idleness. Motor and driven equipment shall be direct coupled and mounted on a common baseplate.

1.08.00

CABLES Insulated armoured power /control cable shall be FRLS - HR insulated, stranded copper / aluminum conductors and shall be provided in accordance with IS:1753 (latest edition) and IS:1554 (Part-I) (latest edition). Trailing cables in the elevator shaft should be specially designed for the specific service and shall conform to IS. Trailing cables shall be EPR insulated for 1.1 kV and shall be neoprene jacketed flexible cord. Conductor accessories including terminal materials like glands, lugs etc. markers, tying materials, and cable supports shall be furnished and installed.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-17 ELEVATOR

PAGE 5 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS Earthing (a.) GENERAL Complete earthing system shall be furnished for all equipments and accessories of the elevator as per relevant IS. (b.) MATERIALS The earthing of all electrical items being supplied by the Contractor shall be in his scope. For earthing the various equipment, conductor sizes shall be as listed below : (1.) Motor above 5 kW upto 30 kW 25x6 mm2 GI flat (2.) Motors upto 5 KW and misc. small item like conduits, junction boxes etc. (3.) Cab earthing 8 SWG GI wire

1.09.00

Additional core of trailing cable

The earthing strip/wire shall be connected to the earthing mat by the Contractor. Clamps and other hardware of iron or steel used with the grounding system shall be hot-dip galvanised. Bolts, washers, and nuts shall be hot-dip galvanised steel.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-17 ELEVATOR

PAGE 6 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET : ELEVATOR

1.0.0 1.1.0 2.0.0 2.1.0 2.2.0 2.3.0

GENERAL Type of Service DESIGN & CONSTRUCTION Carrying capacity Rated speed Total Travel 1000 Kg Approx 25 - 40 mtrs / min. Shall be as per actual dimension of the Building As per requirement As per requirement 1.3m x 2.0m x 2.1 m Suitable for working floors as indicated in the tender drawing. One (1) No. 6 mm thk. Al. Chequered plate. Passenger-Cum-Goods

2.4.0 2.5.0 2.6.0 2.7.0

No. of floors to be served Entrance Min. cab Floor size (inside) WxLxH Various heights of landing floors to be served

2.8.0 2.9.0

Drive Motors (AC) Cab Flooring

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-17 ELEVATOR

PAGE 7 OF 7

PART - B SUB-SECTION-IIIA-18 APRON FEEDER

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

APRON FEEDER 1.00.00 GENERAL Apron feeders complete with all accessories shall be furnished for wagon tippler hoppers as specified. 2.00.00 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 performance 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 Employer shall be final and binding. 3.00.00 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 dribble 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. 4.00.00 CONSTRUCTION REQUIREMENT The frame shall be manufactured from rolled steel section welded and bolted together to form a rigid structure. 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 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 provided for the tensioning of the chain.
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-18 APRON FEEDER PAGE 1 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, stringers, deck plates etc. shall be provided.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-18 APRON FEEDER

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEET

Angle of Installation Chain Link

: :

Horizontal Forged alloy Steel

Apron pan

MS fabricated with wear resistant plate or special alloy steel .


Cast Steel Forged Alloy Steel
VVVF/Hydraulic

Traction wheel Rollers


Drive

: :
:

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-18 APRON FEEDER

PAGE 3 OF 3

PART - B SUB-SECTION-IIIA-19 SIDE ARM CHARGER

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

SIDE ARM CHARGER 1.00.00 1.01.00 GENERAL Side Arm Charger shall be furnished complete with travel rails, drive equipments and associated accessories. 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. 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 stipulated by RDSO. 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 Project Manager shall be final and binding. 3.00.00 3.01.00 DESIGN REQUIREMENT A single module of side arm charger shall be used for inhaul and outhaul operations. The side Arm charger shall be suitable to handle 58 numbers of loaded wagons. Thus, side arm charger shall be used for indexing forward the rake of 58 nos. loaded wagons, placing decoupled wagons on the tippler table and out hauling the empty wagons. The rake of 58 loaded wagons will be brought by locomotive and placed on the pretipping 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, pull the rake of 58 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. Now the leading wagon will be placed 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 from the loaded wagon. Adequate clearance between tippler table 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 and the machine will move towards in-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.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-19 SIDE ARM CHARGER PAGE 1 OF 3

1.02.00

2.00.00

3.02.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS CONSTRUCTION REQUIREMENT The Side Arm Charger shall be suitable to handle 58 number of loaded wagons. The pusher arm shall be vertically Rota table arm mounted on a carriage running back and forth parallel to the train track. The arm shall be raised to clear the movement of 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. The arm shall be raised and lowered by means of hydraulic cylinder mounted on the carriage. Suitable means shall be provided to prevent damage to the arms should the arm be accidentally lowered into the side of wagon. The arm shall be of robust construction either of cast steel or of heavy duty fabricated steel for the required duty. 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. The carriage frame shall be a suitable fabrication assembly of large proportions massive enough in strength and rigidity for the required duty. Travel Carriage Drive System 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. The rating of the drive equipment and its characteristics shall match with indexing forces required to be exerted in varying amounts depending upon train dynamics and to suit haulage of 58 wagon loaded rake. 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 positioner arm to the foundation. The wheels/rollers shall be of forged steel and shall run on the rails supported over the RCC pedestal. 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.

4.00.00 4.01.00

4.02.00

4.03.00

4.04.00

4.05.00

4.06.00

4.07.00 4.07.01

4.08.00

4.09.00

4.10.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-19 SIDE ARM CHARGER

PAGE 2 OF 3

CLAUSE NO.

TECHNICAL REQUIREMENTS

DATA SHEETS

1.0.0

DESIGN & CONSTRUCTION REQUIREMENTS Arm : Robust construction either of cast steel or heavy duty fabricated steel. Hydraulic cylinder Single fabrication assembly.

1.1.0

1.2.0 1.3.0 1.4.0 1.4.1 1.4.2 1.4.3

Arm Drive Carriage Frame Travel Carriage drive Motor Travel brake Bearings for sheaves

: : : : : :

Hydraulic motor driving through a gear box. Integral part of hydraulic motor Anti friction bearings.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-19 SIDE ARM CHARGER

PAGE 3 OF 3

PART - B ELECTRICAL

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PART - B SUB-SECTION-IIIB-01 MOTORS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS MOTORS

1.00.00 1.01.00

GENERAL REQUIREMENTS For the purpose of design of equipment/systems, an ambient temperature of 50 deg. centigrade and relative humidity of 95% shall be considered. The equipment shall operate in a highly polluted environment. All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% & -5%, and 10% combined variation of voltage and frequency unless specifically brought out in the specification. Contractor shall provide fully compatible electrical system, equipments, accessories and services. All the equipment, material and systems shall, in general, conform to the latest edition of relevant National and international Codes & Standards, especially the Indian Statutory Regulations. The auxiliary AC voltage supply arrangement shall have 11kV, 3.3 kV and 415V systems. It shall be designed to limit voltage variations as given below under worst operating condition: (a) 11kV, 3.3 kV (b) 415/240V +/- 6% +/- 10%

1.02.00

1.03.00

1.04.00

1.05.00

1.06.00

The voltage level for motors shall be as follows :a) Upto 0.2KW : 240V, Single Phase AC/ 415V Three phase AC 415V, Three Phase AC 3.3 kV, Three Phase AC 11KV,Three Phase AC

b) c) d)

Above 0.2KW and upto 200KW Above 200KW and upto 1500KW Above 1500KW

: : :

For CHP conveyors motor above 160 kW rating 3.3 KV, three phase AC supply is to be used. However all the motors on the S/R machine shall be on 415 AC only. 1.07.00 Fault level shall be limited to 40kA RMS for 1 second for 11kV & 3.3kV system and 45 kA RMS 1 second for 415V system. 415V system shall be solidly grounded and 220 VDC system shall be isolated type. Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor motors.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-01 MOTORS

1.08.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 1 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS The responsibility of coordination with electrical agencies and obtaining all necessary clearances shall be of the contractor. Degree of Protection Degree of protection for various enclosures as per IS:4691, IEC60034-05 shall be as follows :i) ii) iii) Indoor motors Outdoor motors CW motors (in case of screen prot. Drip proof) Cable box - indoor area Cable box - outdoor area IP 54 IP 55 IP 23

1.09.00

1.10.00

iv) v) 2.00.00

IP 54 IP 55

CODES AND STANDARDS 1) 2) 3) 4) 5) Three phase induction motors : Single phase AC motors Crane duty motors DC motors/generators Energy Efficient motors : : : : IS:325, IEC:60034 IS:996, IEC:60034 IS:3177, IEC:60034 IS:4722 IS 12615

3.00.00 3.01.00

TYPE AC Motors: (a) (b) Squirrel cage induction motor suitable for direct-on-line starting. Continuous duty LT motors upto 160 KW Output rating (at 50 deg.C ambient temperature), shall be Energy Efficient motors, Efficiency class-Efficiency 1, conforming to IS 12615. Crane duty motors shall be slip ring/ squirrel cage Induction motor as per the requirement. Shunt wound.

(c)

3.02.00

DC Motors:

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-01 MOTORS

PAGE 2 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS RATING (a) Continuously rated (S1). However, crane motors shall be rated for S4 duty, 40% cyclic duration factor. Whenever the basis for motor ratings are not specified in the corresponding mechanical specification sub-sections, maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations.

4.00.00

(b)

5.00.00

TEMPERATURE RISE Air cooled motors 70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation. Water cooled 80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance method for both thermal class 130(B) & 155(F) insulation .

6.00.00 6.01.00 6.01.01

OPERATIONAL REQUIREMENTS Starting Time For motors with starting time upto 20 sec. at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be at least 2.5 sec. more than starting time. For motors with starting time more than 20 sec. and upto 45 sec. at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be at least 5 sec. more than starting time. For motors with starting time more than 45 sec. at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be more than starting time by at least 10% of the starting time. Speed switches mounted on the motor shaft shall be provided in cases where above requirements are not met. Torque Requirements Accelerating torque at any speed with the lowest permissible starting voltage shall be at least 10% motor full load torque.

6.01.02

6.01.03

6.01.04

6.02.00 6.02.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-01 MOTORS

PAGE 3 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall be 275% for crane duty motors. Starting voltage requirement (a) 85% upto 1500KW (d) 80% from 1501 KW to 4000KW (c) 75% > 4000KW

6.02.02

6.03.00

7.00.00 7.01.00

DESIGN AND CONSTRUCTIONAL FEATURES Suitable single phase space heaters shall be provided on motors rated 30KW and above to maintain windings in dry condition when motor is standstill. Separate terminal box for space heaters & RTDs shall be provided. However for flame proof motors, space heater terminals inside the main terminal box may be acceptable. All motors shall be either Totally enclosed fan cooled (TEFC) or totally enclosed tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors can be screen protected drip proof (SPDP) type. Motors located in hazardous areas shall have flame proof enclosures conforming to IS:2148 as detailed below (a) (b) Fuel oil area Hydrogen generation plant area : Group - IIB : Group - IIC (or Group-I, Div-II as per NEC)

7.02.00

7.03.00

Winding and Insulation (a) (b) Type Starting duty : : Non-hygroscopic, oil resistant, flame resistant Two hot starts in succession, with motor initially at normal running temperature Thermal Class 155(F) insulation with winding temperature rise limited to thermal class 130(B). The winding insulation process shall be total Vacuum Pressure Impregnated i.e. resin poor method. The lightning impulse & Inter-turn insulation surge withstand level shall be as per IEC-60034 Part-15. Thermal Class130(B) or better

(c)

11kV, 3.3 kV AC motors

(d)

415V AC & 220V DC : motors

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-01 MOTORS

PAGE 4 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft currents. Motors with heat exchangers shall have dial type thermometer with adjustable alarm contacts to indicate inlet and outlet primary air temperature. Noise level for all the motors shall be limited to 85dB(A). Bearing housing vibration shall be limited within the limits prescribed in IEC 60034-14/IS:12075 . Motors shall withstand vibrations produced by driven equipment. HT motor bearing housings shall have flat surfaces, in both X and Y directions, suitable for mounting 80mmX80mm vibration pads. In HT motors, at least four numbers simplex / two numbers duplex platinum resistance type temperature detectors shall be provided in each phase stator winding. Each bearing of HT motor shall be provided with dial type thermometer with adjustable alarm contact and minimum 1(one) number duplex platinum resistance type temperature detectors. Motor body shall have two earthing points on opposite sides. HT motors can be offered with either elastimold termination or dust tight phase separated double walled (metallic as well as insulated barrier) cable boxes. In case elastimold terminations are offered, then protective cover and trifurcating sleeves shall also be provided. In case cable box is offered, then Employer shall provide termination kit. Removable gland plates of thickness 3 mm (hot/cold rolled sheet steel for three core cables) or 4 mm (non magnetic material for single core cables) shall be provided in case of cable boxes. The spacing between gland plate & centre of terminal stud shall be as per Table-I. All motors shall be so designed that maximum inrush currents and locked rotor and pullout torque developed by them at extreme voltage and frequency variations do not endanger the motor and driven equipment. The motors shall be suitable for bus transfer schemes provided on the 11kV, 3.3 kV/415V systems without any injurious effect on its life. For motors rated 2000 KW & above, neutral current transformers of PS class shall be provided on each phase in a separate neutral terminal box. 11KV and 3.3KV motors Terminal Box shall be suitable for fault level of 750MVA for 0.12 sec and 250MVA for 0.12 sec respectively. The size and number of cables (for HT and LT motors) to be intimated to the successful bidder during detailed engineering and the contractor shall provide terminal box, cable glands & lugs suitable for the same.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-01 MOTORS

7.04.00

7.05.00

7.06.00

7.07.00

7.08.00 7.09.00

7.10.00 7.11.00

7.12.00

7.13.00

7.14.00

7.15.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 5 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the following (without any further tolerance). (a) Upto 110KW (b) Above 110KW & upto 1500KW (c) Above 1500KW & upto 4000KW : : : : 11.0 10.0 9.0 6 to 6.5

7.16.00

(d) Above 4000KW 7.17.00 8.00.00 8.01.00 8.01.01

CW motors shall be designed with minimum power factor of 0.8 at design duty point. TYPE TEST HT MOTORS The contractor shall carry out the type tests as indicated in the "LIST OF TYPE TESTS TO BE CONDUCTED on the equipment mentioned there in. The Bidder shall indicate the charges for each of these type tests separately in the relevant schedule of BPS and the same shall be considered for the evaluation of the Bids. The type test charges shall be paid only for the test(s) actually conducted successfully under this contract and upon certification by the Owner's Engineer. The type tests shall be carried out in presence of the Owner's representative, for which minimum 15 days notice shall be given by the Contractor. The Contractor shall obtain the Owner's approval for the type test procedure before conducting the type test. The type test procedure shall clearly specify the test set-up, instruments to be used, procedure, acceptance norms, recording of different parameters, interval of recording, precautions to be taken etc. for the type test(s) to be carried out. In case the contractor has conducted such specified type test(s) within last ten years as on the date of bid opening, he may submit the reports of the type tests indicated in the "LIST OF TYPE TESTS TO BE CONDUCTED " to the owner for waival of conductance of such type test(s).These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The Owner reserves the right to waive conducting of any or all of the specified type test(s) under this contract. In case type tests are waived, the type test charges shall not be payable to the contractor. Further the Contractor shall only submit the reports of the type tests as listed in "LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-01 MOTORS

8.01.02

8.01.03

8.01.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 6 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS laboratory or should have been witnessed by a client. In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract free of cost to the Owner and submit the reports for approval.

8.01.05

LIST OF TESTS TO BE CONDUCTED The following type tests shall be conducted on each type and rating of HT motor (a) (b) (c) (d) (e) No load saturation and loss curves upto approximately 115% of rated voltage Measurement of noise at no load. Momentary overload test (subject to test bed constraint). Full load test (subject to test bed constraint). Temperature rise test at rated conditions. During heat run test, bearing temp., winding temp., coolant flow and its temp. shall also be measured. In case the temperature rise test is carried at load other than rated load, specific approval for the test method and procedure is required to be obtained. Wherever ETD's are provided, the temperature shall be measured by ETD's also for the record purpose.

8.01.06

LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED The following type test reports shall be submitted for each type and rating of HT motor (a) Degree of protection test for the enclosure followed by IR, HV and no load run test. Terminal box-fault level withstand test for each type of terminal box of HT motors only. Lightning Impulse withstand test on the sample coil shall be as per clause 5.1.3.2, IEC-60034,Part-15. Surge withstand voltage test on inter-turn insulation as per IEC 60034-15

(b) (c) (d) 8.02.00 8.02.01

LT Motors LT motors shall be of type tested design. For each type & rating of LT motors rated above 50 KW, the contractor shall submit for Owner's approval the reports of all the type tests as per relevant standards and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-01 MOTORS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 7 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.

8.02.02

In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

8.03.00

8.04.00

TABLE - I DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS: Motor MCR in KW centre of stud and gland UP to 3 KW Above 3 KW - upto 7 KW Above 7 KW - upto 13 KW Above 13 KW - upto 24 KW Above 24 KW - upto 37 KW Above 37 KW - upto 55 KW Above 55 KW - upto 90 KW Above 90 KW - upto 125 KW Above 125 KW-upto 200 KW Minimum distance between plate in mm As per manufacturer's practice. 85 115 167 196 249 277 331 203

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-01 MOTORS

PAGE 8 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS FOR HT MOTORS: The distance between gland plate and the terminal studs shall not be less than 500 mm. PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE: NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs installed shall be as follows: Motor MCR in KW UP to 110 KW Above 110 KW and upto 150 KW Above 150 KW Clearance 10mm 12.5mm 19mm

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-01 MOTORS

PAGE 9 OF 9

PART - B SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUS DUCT

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS LT SWITCHGEAR & BUSDUCT

1.00.00 2.00.00

CODES AND STANDARDS IEC: 60947, IS : 13947, IEC: 60439,IS:8623,IEC:61850 TYPE Circuit Breakers Shall be air break, three pole, spring charged, horizontal drawout type, suitable for electrical operation. Fully drawout type single front Fully drawout type single front/Double front. Fixed type single front

Switchgear MCC ACDB/DCDB 3.00.00 SYSTEM PARAMETERS

415VAC +/- 10 %(SOLIDLY GROUNDED) 50 Hz +3%/-5% 45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL) 220V DC NOMINAL (190V DC-240V DC) ISOLATED TYPE FOR ASH HANDLING SYSTEM 4.00.00 TEMPERATURE RISE The temperature rise of the horizontal and vertical busbars and main bus link including all power draw out contacts when carrying 90% of the rated current along the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C with all other types of joints over an ambient of 50 deg C. The temperature rise of the accessible parts/external enclosures expected to be touched in normal operation shall not exceed 20 deg.C. The temperature rise of manual operating means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material. The above temperature rise limits are applicable for busducts also without any current derating. 5.00.00 5.01.00 5.01.01 OPERATIONAL REQUIREMENTS Breakers Breakers shall have anti-pumping feature.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 1 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS The incomer and bus coupler breakers for switchgear shall be electrically operated with Numerical communicable relays. Breakers shall have inherent fault making and breaking capacities. They shall have shunt trip coils. All breakers shall have built in interlocks for equipment and personnel safety. Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover is provided. Breaker contact multiplication, if required, shall be through latch relay. Mechanical tripping shall be through red Trip push button outside the panels for breakers, and through control switches for other circuits. Provision of mechanical closing of breaker only in Test and Withdrawn position shall be made. Alternatively, mechanical closing facility should be normally inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall be possible to close the door with breaker in test position. Clear status indication for each circuit shall be provided through lamps, switch positions or other mechanical means. Switches, Contactors and Fuses Incomers for MCCs and DBs rated below 250A could be load break isolators. Motor starter contactors shall be of air break, electromagnetic type suitable for DOL starting of motor, and shall be of utilisation category AC-3 for ordinary and AC-4 for reversing starters. For conveyor motors, minimum rating of power contactors shall be 200% of the full load current of the motors. For other motors minimum rating of power contactors shall be 160% of full load current of motor. DC contactor shall be of DC-3 utilisation category. Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC 23A category when used in motor circuit, and AC 22A category for other applications. Fuse switch combination shall be provided wherever possible. The 250A & above feeders up to 630A shall have MCCB.MCCB shall be provided with Microprocessor based inbuilt front adjustable releases(overload & short circuit) and shall have adjustable earth fault protection unit also . MCCB shall have current limiting feature. ON and OFF position of the operating handle of MCCB shall be displayed and the rotary operating handle shall be mounted on the door of the compartment housing MCCB. The compartment door shall be interlocked mechanically with the MCCB, such that the door can not be opened unless the MCCB is in OFF position. Means shall be provided for defeating this interlock at any time MCCB shall be provided with padlocking facility to enable the operating mechanism to be padlocked.

5.01.02

5.01.03

5.01.04

5.01.05

5.01.06

5.01.07

5.02.00 5.02.01 5.02.02

5.02.03

5.02.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 2 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS Panels All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall have prominent engraved indentification plates. Local push button stations shall have metal enclosure of die cast aluminium or rolled sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in case the same are located in dusty areas. Push buttons shall be of latch type with mushroom knobs. Where breaker/starter module front serves as compartment cover, suitable blanking covers, one for each size of modules per switchboard shall be supplied for use when carriage is withdrawn. All non-current carrying metal work of boards/panels shall be effectively bonded to earth bus of galavanised steel, extending throughout the switchboard/MCC/DB. Positive earthing shall be maintained for all positions of chassis and breaker frame. Suitable trolley arrangement shall be provided for breaker/starter modules. Two trolleys per switchgear room shall be provided so that top most breaker module of all types, sizes and rating can be withdrawn on trolley and lowered for maintenance purpose. The incoming connection to transformer of more than 1000KVA and inter-connecting sections between switchboards shall preferably be of bus ducts. The bus duct enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the bus duct should have adequate strength to withstand internal and external forces resulting from the various operating conditions. Aluminium sheet hood shall be provided for outdoor bus duct enclosure joints to provide additional protection against water ingress. The bus duct top shall be sloped to prevent retention of water. The bus duct enclosure shall have DOP of IP55 and paint shade RAL 5012. It should be possible to carryout maintenance on a feeder with adjacent feeders alive. DC fuse board shall consist of: -1 no.63A switch as incomer with meters, lamps and auxiliary contactors. -8 nos. outgoing feeders with 16A HRC fuses.

5.03.00 5.03.01

5.03.02

5.03.03

5.03.04

5.03.05

5.03.06

5.03.07

5.03.08

5.03.09

AC fuse board shall consist of: -1 no 63A TPN SFU as incomer with lamps and meters. -9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 3 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS Welding distribution board (WBD) to be located in MCC room shall consist of: a) One (1) no. welding transformer (415/433 V, delta/star, epoxy insulated, air cooled, dry type). Transformer shall be 50 KVA/100 KVA for upto 10/15 nos outgoing feeders. TPN SFU on primary and secondary side of the transformer 63 A TPN SFU as outgoing feeders including 20 % spare. Voltmeter, ammeter with selector switches, indicating lamps.

5.03.10

b) c) d) 5.03.11

Main lighting distribution board(MLDB) to be located in MCC room shall consist of:a) Two(2) nos. x 100% rated, lighting transformers (415V/433V, delta/star, epoxy insulated, air cooled, dry type). Transformer shall be 50KVA\100KVA rating for 10/15 nos. outgoing feeder. TPN SFU on primary and secondary side of the transformer 63A TPN SFU as outgoing feeders including 20% spare. Voltmeter, ammeter with selector switches, indicating lamps. The two incomers (One from Bus-A and One from Bus-B of the MCC) and one bus-coupler for the power supply to each MLDB shall be provided with castle key networks.

b) c) d) e)

5.04.00 5.04.01

Control, Protection & Metering Requirements Control circuits shall operate at suitable voltage of 110V AC or 220V DC/110V DC. Necessary control supply transformers having primary and secondary fuses shall be provided for each MCC, 2 x 100% per bus section. However the breakers shall operate on 220V DC The auxiliary bus bars for control supply shall be segregated from main bus bars. The control supplies shall be monitored. Contractor shall fully co-ordinate overload and short circuit tripping of breaker with upstream and down stream breakers/fuses/MCCBs motor starters. Various equipments shall meet requirement of Type-II class of coordination as per IEC. The protective relays shall be communicable numerical relays These numerical relays shall be of types as proven for the application and shall be subject to Employers approval Numerical relays shall have appropriate setting ranges, accuracy, resetting ratio and other characteristics to provide required sensitivity.All equipments shall have necessary protections as detailed in the standard scheme drawings.

5.04.02

5.04.03

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 4 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS All equipments shall have necessary protections. However, following minimum protections shall be provided:

5.04.04

1)

Contactor controlled motor feeders (Motors up to 160KW) a) Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 415V). Thermal overload protection Single phasing protection for motors protected by fuses

b) c) 2)

Incomers / buscoupler / outgoing breaker feeders other than motor feeders. a) Three phase over current protection (50) b) Three phase earth fault protection (50N3)

c) Restricted earth fault protection for transformer incomers(64R) d) Sync Check 5.05.00 5.05.01 General requirements of Numerical Relays All relays and timers shall be rated for control supply voltage as mentioned elsewhere under parameters and shall be capable of satisfactory continuous operation between 80-120% of the rated voltage. Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to ensure avoidance of mal operation due to stray voltages. All Numerical relays shall have communications on two ports, local front port for communication to laptop and a second port on IEC 61850 to communicate with owners data concentrator through LAN. All Numerical Relays shall have features for electrical measurement including voltage, current, power (active / reactive) and energy parameters. All Numerical Relay shall have key pad / keys to allow relay settings from relay front. All hand reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. Manual resetting shall be possible from remote.

5.05.02

5.05.03

5.05.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 5 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS The protective relays shall have at least 10 Nos. programmable potential free contacts. Programmable Auxiliary relays shall have contacts as required. For control from DDCMIS, 24V DC signal shall be provided from DDCMIS to the numerical relays. Preferably, no separate coupling relays shall be provided. Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker trip circuit both in pre trip and post trip conditions. Schematics requiring auxiliary relays / timers for protection function shall be a part of Numerical Relay. The number of auxiliary relay and timer function for protection function shall be as required by the scheme. Auxiliary relays for interlocking purpose shall be of self reset type. The numerical processor shall be capable of measuring and storing values of a wide range of quantities, all events, faults and disturbance recordings with a time stamping using the internal real time clock. Battery back up for real time clock in the event of power supply failure shall be provided. Sequence of events shall have 1ms resolution at device level. Ethernet switches shall be substation hardened and shall comply to IEC61850-3 for communications and environment requirements. The Ethernet switches shall be of managed type with required number of ports to achieve the owners LAN configuration. One(1) no. Ethernet switch per switch board shall be provided & these switches shall be mounted inside the switchgear Panels. In case of remote controlled breaker panels, following shall be ensured. The circuit breaker will normally be controlled from remote control panels (employers DDCMIS) through closing and shunt trip coils. The Local control console of the relay flush mounted on the switchgear would normally be used only for testing of circuit breaker in isolated position, and for tripping it in an emergency. Provision for closing & tripping of the circuit breaker locally from laptop through serial port shall be possible to facilitate commissioning activities. The basic control scheme of breaker feeders shall be developed as per the schematic logics in the relay. The schematics shall be developed in soft inside the relay. Numerical relays shall be interfaced with employers DDCMIS through 24V DC signal for closing / opening operations.

5.05.05

5.05.06

5.05.07

5.05.08

5.05.09

5.05.10 5.05.11

5.05.12

5.05.13

Hardwired contacts from the relay shall be wired to PLC / DCS system as per requirements. The numerical relay shall be capable of measuring and storing values of a wide range of quantities, events, faults and disturbance recordings. The alarm / status of each of protection function and trip operation shall be communicated to PLC/DCS. The numerical relays shall have built in feature / hardware interface to provide such inputs to PLC / DCS for analog / digital values..
SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

5.05.14

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 6 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS It shall be possible to carryout open / close operation of breakers from a laptop by interfacing from the relay front port (RS232) during initial commissioning. Meters / instruments All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size with 90 degree linear scales and accuracy class of 2.0.

5.05.15

5.06.00

5.06.01

All motors of 30kW and above upto 100 kw shall have an Ammeter & current transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and other relay and timers required for protection. Adequate control and selector switches, push buttons and indicating lamps shall be provided. Thermostatically controlled space heaters with switches shall be provided to prevent condensation. For all motor feeders related to dust suppression system and for all other motor feeders having 100KW & above rating, contractor shall provide multifunction Digital Energy Meter with communication facility to display the current, voltage, power factor, power, energy related data locally and shall communicate these for remote metering /audit/analysis purposes. The technical specification for Digital indicating energy meter shall be as follow: a) b) c) d) e) f) g) h) i) j) k) l) m) n) Input Voltage: 110 V AC/220 V DC Input Current:1A Size: 96X96 SQ.MM Accuracy:1.0% for power & energy Mounting: Flush mounting Type:True RMS 3-PHASE V, I,KW,PF & KWHr indication 4 Digit, seven segment LED display/LCD display, with floating decimal Communication: In built RS 485 serial bus port Operating Frequency: 45 HZ-65HZ Dielectric Test: 2KV RMS for 1 minute Over current: 10 times for 3 sec. Aux. supply: 90V-300V AC/DC Compliance: EMC/EMI Field programmable CT ratio

5.06.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 7 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS Control from Remote Necessary hardware shall be provided in the switchgear panel like coupling relays (if required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information / status and exercise control from remote.

5.07.00

6.00.00 6.01.00

DESIGN AND CONSTRUCTIONAL FEATURES All 415V switch gear motor control centers (MCCs), AC & DC distribution boards (DB s), etc shall have following features : 1) Shall be of metal enclosed, indoor, floor mounted and free standing type. All frames and load bearing members shall be fabricated using mild steel structural sections or pressed and shaped cold rolled sheet steel of thickness not less than 2mm. Frame shall be enclosed in cold rolled sheet steel of thickness not less than 1.6mm.Doors and covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever necessary. Removable gland plates of thickness 3mm (hot/cold rolled sheet steel) or 4 mm (non-magnetic material) shall be provided for all panels. All switchboards/panels shall be of dust and vermin proof. All cutouts shall have EPDM/Neoprene gaskets. All switchboards, MCCs and DB s shall have following distinct vertical sections. a) Completely enclosed bus bar compartment for horizontal and vertical bus bars. Completely enclosed switchgear compartments (one for each circuit housing circuit breakers, motor starter or switch-fuse feeder). Compartment for cable alley or cable box for power and control cables. In case of cable box, they shall be segregated with complete shrouding for individual feeders at the rear for direct termination of cables.

2)

3)

4)

5)

b)

c)

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SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 8 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS

d)

For cable connection to circuit breaker, a separately enclosed cable compartment shall also be acceptable. Compartment for relays and other control devices associated with a circuit breaker, wherever necessary. The switchboards/MCC/DBs of 1600A & above rating shall be of DOP IP42 & of IP52 for less than 1600A rating. All 415V switchgears, MCCs, AC & DC distribution boards etc. shall be painted by powder coating process. Paint shade for complete panels excluding end covers shall be RAL9002 & RAL5012 for extreme end covers of all boards. All draw out modules shall have distinct service, test and isolated positions with provision of external pad locking facility in each position. Power contacts shall get disconnected in both test and isolated positions whereas the control contacts shall get disconnected in isolated position only.

e)

f)

g)

h)

6) 7)

Busbars shall be of high conductivity aluminium alloy or copper. The cross section of the horizontal bus bars shall be uniform through out the length of the switchboard and both horizontal as well as vertical bus bars shall be adequately supported and braced to withstand the stresses due to the specified short circuit currents. Neutral bus bar short circuit strength shall be same as the main bus bars. Minimum air clearance in air between phases and phase-earth shall be 25 mm for busbars and cable terminations. For all other components, the Clearances shall be at least 10mm. Wherever above is not possible except for horizontal and vertical busbars, insulation shall be provided by anti tracking sleeving or barriers. However for horizontal and vertical busbars, clearances specified above shall be maintained even when busbars are insulated/sleeved. In case of DC DBs/ fuse boards, the busbar system shall be insulated or physically segregated with barriers to prevent interpole short circuit. Busbar insulators shall be of track-resistant high strength non-hygroscopic, non-combustible type and suitable to withstand stresses due to over-voltages and short circuit current. Insulators and barrier of inflammable material such as Hylam shall not be accepted. All types of relays and timer shall be subject to Employers approval. They shall be flush mounted with connections from inside, and shall have transparent & dust tight cover, removable from front, drawout construction for easy replacemernt and testing facility. The auxiliary relays and timer may be provided in fixed cases.
SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

8)

9)

10)

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PAGE 9 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS

11)

Terminal Blocks Terminal blocks shall be 650V grade, 10Amps rated, made up of unbreakable polyamide 6.6 grade. The terminals shall be either screw type or screw-less (spring loaded) / cage clamp type with lugs. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be of non-ferrous material. In case of screw type terminals the screw shall be captive, preferably with screw locking design. Maxi terminal / cage clamp type terminal blocks shall be provided for signals to be interfaced with DDCMIS / PLC.

12)

The switchgears/MCC shall be designed to offer adequate level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of switchgear/MCC. All current and voltage transformers as required for metering & protection specified shall be completely encapsulated cast resin insulated type. Incomers from transformers shall have CTs for transformer REF protection. The accuracy shall be as follows: CTs PTs 3P 0.5

13)

Protection Metering REF 6.02.00

5P20,5VA 1.0 PS

Indicating lamps shall be cluster LED type.All overload relays shall have overload reset push button. Switchgear/MCC shall have bottom cable entry. Contractor shall provide minimum one spare feeder for each type and rating of the out going feeders on each MCC. TYPE TESTS GENERAL (a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

6.03.00 6.04.00

7.00.00 7.01.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 10 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. (b.) In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost either at third party lab or in presence of client/ownerss representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No design Change. Minor changes if any shall be highlighted on the endorsement sheet.

(c.)

(d.)

7.03.00

L. T. SWITCHGEAR The following type test certificates on each type & rating of L.T. Switchgear and MCC panel shall be submitted. (a.) (b.) (c.) Short time withstand test. Temperature rise test. Class II - Protection co-ordination test for any three ratings of MCC module as selected by employer Test sequence 1 & combined test sequence on each rating of circuit breaker mounted inside the panel. Degree of protection tests Type test certificates for Numerical relays.

(d.)

(e.) (f.)

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SUB-SECTION-IIIB-02 LT SWITCHGEAR & BUSDUCT

PAGE 11 OF 11

10/01/07

10/01/07

10/01/07

10/01/07

10/01/07

10/01/07

PART - B SUB-SECTION-IIIB-03 HT CABLES

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS HT CABLES

1.00.00 1.01.00

CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS: codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes : IS:7098 (Part -II) Specification for Cross-linked polyethylene insulated PVC sheathed cables. Part-II: For working voltages from 3.3 KV upto and including 33 KV. Low Carbon Galvanized steel wires, formed wires and tapes for armouring of cables. Methods for random sampling. PVC insulation and sheath of electrical cables. Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. Tests on gases evolved during combustion of electric cables. Tests on electric cables under fire conditions. Part-3: Tests on bunched wires or cables (Category-B).

IS : 3975

IS : 4905 IS : 5831 IS : 8130 IS : 10418 IS : 10810 ASTM-D -2843

IEC-754 (Part-I) IEC-332

2.00.00 2.01.00

TECHNICAL REQUIREMENTS The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground (buried) installation with chances of flooding by water. Cables shall be 6.6/6.6KV grade, Aluminium conductor, XLPE insulated, PVC inner sheath, Armoured, Flame retardant low smoke (FRLS) PVC outer sheathed, designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions. Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-03 HT CABLES

2.02.00

2.03.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 1 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS XLPE insulation shall be suitable for continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831. For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows: Calculated nominal dia of cable under armour i) ii) iii) iv) v) vi) Upto 13 mm Above 13 & upto 25mm Above 25 & upto 40 mm Above 40 & upto 55mm Above 55 & upto 70mm Above 70mm Size and Type of armour

2.04.00

2.05.00

2.06.00

1.4mm dia GS wire 0.8 mm thick GS formed wire/1.6 mm dia GS wire 0.8mm thick GS formed wire/2.0mm dia GS wire 1.4 mm thick GS formed wire/2.5mm dia GS wire 1.4 mm thick GS formed wire/3.15mm dia GS wire 1.4 mm thick GS formed wire/4.0 mm dia GS wire

2.06.01

The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum resistivity of 0.028264 ohm-sq.mm/mtr at 20 deg.C. The types and sizes of aluminium armouring shall be same as mentioned for galvanised steel above. The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wires / formed wires. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of GS wires/formed wires. Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided for all cables. Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties. (a.) Oxygen index of min. 29 (Test method as per IS 10810 Part-58)

2.06.02

2.06.03

2.07.00

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SUB-SECTION-IIIB-03 HT CABLES

PAGE 2 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS (b.) (c.) Acid gas emission of max. 20% as per IEC-754 (Part-I) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.

2.08.00

Cores of three core cables shall be identified by colouring of insulation or by providing coloured tapes helically over the cores, with Red, Yellow & Blue colours. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath : Cable size and voltage grade Word 'FRLS' at every 5 metre Screen fault current 300A for 2 sec. Sequential marking of length of the cable in metres at every one metre to be embossed / printed : : To be embossed To be embossed

2.09.00

The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible. 2.10.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3. Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable. The cross-sectional area of the metallic screen strip/tape/wires shall be considered in sizing calculations. Cable selection & sizing HT cables shall be sized based on the following considerations: a) b) Rated current of the equipment The voltage drop in the cable, during motor starting condition shall be limited to 10% and during full load running condition it shall be limited to 3% of the rated voltage. Short circuit withstand capability

2.11.00

2.12.00

2.13.00

2.14.00 2.14.01

c)

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SUB-SECTION-IIIB-03 HT CABLES

PAGE 3 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS Derating Factors Derating factors for various conditions of installations including the following shall be considered while selecting the cable sizes: a) b) c) Variation in ambient temperature for cables laid in air Grouping of cables Variation in ground temperature and soil resistivity for buried cables.

2.14.02

2.14.03

Cable lengths shall be considered in such a way that straight through cable joints are avoided. CONSTRUCTIONAL FEATURES 6.6KV/6.6KV Grade Power Cables Cables shall conform to IS: 7098 Part - II. These cables shall be multi- stranded, compacted circular aluminium conductors, XLPE insulated, metallic screened, PVC inner sheathed, armoured and FRLS PVC outer sheathed. The metallic screen of each core shall consist of copper wires or tape with minimum overlap of 20%. However, for single core armoured cables, the armouring shall constitute the metallic part of the screening. The metallic screen of each core shall be capable of carrying the system earth fault current, 300A for 2sec. Method of curing for cables shall be "dry curing / gas curing / steam curing". The eccentricity of the core shall not exceed 10% and ovality not to exceed 2%.

3.00.00 3.01.00

3.02.00

The eccentricity shall be calculated as :tmax -tmin ------------ x 100 t max and the ovality shall be calculated as dmax -dmin ------------ x 100 d max Where t-max/t-min is the maximum/minimum thickness of insulation and d-max/dmin is the maximum / minimum diameter of the core.

4.00.00 4.01.00

CABLE DRUMS Cables shall be supplied in non-returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-03 HT CABLES

PAGE 4 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS covered with waterproof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.

4.02.00

Each drum shall carry manufacturer's name, purchasers name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. The standard drum length for power cables shall not be less than 500 meters. The length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard drum length. Approval from Employer shall be obtained for supplying cable drum with shorter lengths. TESTS (a) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

4.03.00

5.00.00

(b.)

(c.)

(d)

5.01.00

The reports of the following type tests shall be submitted for each type(voltage grade) & size of the cables:
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-03 HT CABLES

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PAGE 5 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

S. No

Type Test Conductor

Remarks

1.

Resistance test For Armour Wires / Formed Wires

2. 3. 4. 5. 6. 7. 8(a)

Measurement of Dimensions Tensile Test Elongation test Torsion test Wrapping test Resistance test Mass & uniformity of Zinc Coating tests Adhesion test For XLPE insulation & PVC Sheath For GS wires/formed wires only. For round wires only

8(b)

For GS wires/formed wires only

9. 10.

Test for thickness Tensile strength and elongation test before ageing and after ageing Ageing in air oven Loss of mass test Hot deformation test Heat shock test Shrinkage test Thermal stability test For PVC outer sheath only For PVC outer sheath only. For PVC outer sheath only. For PVC outer sheath only

11. 12. 13. 14. 15. 16.

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SUB-SECTION-IIIB-03 HT CABLES

PAGE 6 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

17. 18. 19. 20. 21. 22

Hot set test Water absorption test Oxygen index test Smoke density test Acid gas generation test Flammability test as per IEC-332 Part-3 (Category -B)

For XLPE insulation only For XLPE insulation only For PVC outer sheath only For PVC outer sheath only For PVC outer sheath only For completed cable only

S. No. 1. 2. 3. 4. 5.

Type Test For completed cables Insulation resistance test (Volume Resistivity method) High voltage test Partial discharge test Bending test Dielectric power factor test a) b) As a function of voltage As a function of temperature

6. 7. 5.02.00

Heating cycle test Impulse withstand test

Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality Assurance & Inspection table of H.T. cables indicated elsewhere.

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SUB-SECTION-IIIB-03 HT CABLES

PAGE 7 OF 7

PART - B SUB-SECTION-IIIB-04 LT POWER CABLES

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS LT POWER CABLES

1.00.00 1.01.00

CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes: IS :1554 I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V. Recommended current ratings for cables Low carbon galvanised steel wires, formed wires and tapes for armouring of cables. PVC insulation and sheath of electrical cables. Cross linked polyethylene insulated PVC sheathed cables for working voltages upto and including 1100V. Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics. Test on gases evolved during combustion of electric cables. Standard for type test of Class IE Electric Cables. Tests on Electric cables under fire conditions. Part-3 : Tests on bunched wires or cables (category -B)

IS : 3961 IS : 3975

IS : 5831 IS:7098 (Part -I)

IS : 8130 IS : 10418 IS : 10810 ASTM-D -2843

ASTM-D-2863

IEC-754 (Part-I) IEEE-383 IEC -332

2.00.00 2.01.00

TECHNICAL REQUIREMENTS The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground burried installation with chances of flooding by water.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-04 LT POWER CABLES

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CLAUSE NO.

TECHNICAL REQUIREMENTS Cables shall be armoured, flame retardant, low smoke (FRLS), armoured type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification. Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded. XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg.C. PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831. For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows : Calculated nominal dia cable under armour i) ii) Upto 13 mm Above 13 & upto 25mm of Size and Type of armour 1.4mm dia GS wire 0.8 mm thick GS formed wire / 1.6 mm dia GS wire 0.8mm thick GS formed wire / 2.0mm dia GS wire 1.4 mm thick GS formed wire /2.5mm dia GS wire 1.4mm thick GS formed wire / 3.15mm dia GS wire 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

2.02.00

2.03.00

2.04.00

2.05.00

2.06.00

iii)

Above 25 & upto 40 mm

iv)

Above 40 & upto 55mm

v)

Above 55 & upto 70 mm

vi)

Above 70mm

2.06.01

The aluminium used for armouring shall be of H4 grade as per IS:8130 with maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of aluminium wires/formed wires for armouring shall be same as indicated above in clause 2.06.00 for galvanised steel.

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PAGE 2 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of G.S. wire/formed wire. Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties. (a.) (b.) (c.) Oxygen index of min. 29 (As per ASTMD 2863) Acid gas emission of max. 20% (As per IEC-754-I). Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.

2.06.02

2.07.00

2.08.00

Cores of the cables shall be identified by colouring of insulation. Following colour scheme shall be adopted: 1 2 3 4 core core core core Red, Black, Yellow, Blue Red & Black Red, Yellow & Blue Red, Yellow, Blue and Black

2.09.00 2.10.00

For reduced neutral conductors the core shall be black. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath. (a.) (b.) (c.) Cable size and voltage grade - To be embossed Word 'FRLS' at every 5 metre - To be embossed Sequential marking of length of the cable in metres at every one metre-To be embossed / printed

The embossing shall be progressive, automatic, in line and marking shall be legible and indelible. 2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part -3.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-04 LT POWER CABLES

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CLAUSE NO.

TECHNICAL REQUIREMENTS Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.are not acceptable. Cable selection & sizing Cables shall be sized based on the following considerations: (a) (b) Rated current of the equipment The voltage drop in the cable, during motor starting condition, shall be limited to 10% and during full load running condition, shall be limited to 3% of the rated voltage Short circuit withstand capability This will depend on the feeder type. For a fuse protected circuit, cable should be sized to withstand the let out energy of the fuse. For breaker controlled feeder, cable shall be capable of withstanding the system fault current level for total breaker tripping time inclusive of relay pickup time.

2.12.00

2.13.00

2.14.00 2.14.01

(c)

2.14.02

Derating Factors Derating factors for various conditions of installations including the following shall be considered while selecting the cable sizes: a) b) c) Variation in ambient temperature for cables laid in air Grouping of cables Variation in ground temperature and soil resistivity for buried cables.

2.14.03

Cable lengths shall be considered in such a way that straight through cable joints are avoided. All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated and preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm. CONSTRUCTIONAL FEATURES 1.1 KV Grade Power Cables

2.14.04

3.00.00 3.01.00

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PAGE 4 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS (a.) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor, XLPE insulated, PVC inner-sheathed (as applicable), armoured/ unarmoured, PVC outer-sheathed conforming to IS:7098. (Part-I). 1.1KV grade PVC power cables shall have aluminium conductor (compacted type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as applicable) armoured/ unarmoured, PVC outer-sheathed conforming to IS:1554 (Part-I). 1.1 KV grade Trailing cables shall have tinned copper (class 5) conductor, insulated with heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding 90 deg.C continuous conductor temperature and 250deg C during short circuit, inner-sheathed with heat resistant elastomeric compound, nylon cord reinforced, outersheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound conforming to IS 9968.

(b.)

(c.)

4.00.00

CABLE DRUMS (a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418. Each drum shall carry manufacturer's name, purchasers name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

(b.)

5.00.00

TESTS (a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-04 LT POWER CABLES

(b.)

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CLAUSE NO.

TECHNICAL REQUIREMENTS type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. (c.) All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

(d)

5.01.01

TYPE TESTS The reports for the following type tests shall be submitted on one size each of XLPE/PVC LT Power cables: S.No. Type Test For Conductor 1. 2. 3. 4. Annealing test Tensile test Wrapping test Resistance test For Armour Wires/ Formed Wires 5. 6. 7. 8. 9. 10. 11.(a) Measurement of Dimensions Tensile Test Elongation test Torsion test Wrapping test Resistance test Mass of Zinc Coating test For G.S. Formed wires /wires only.
SUB-SECTION-IIIB-04 LT POWER CABLES

Remarks

For copper conductor only. For aluminium conductor only. For aluminium conductor only.

For round wires only For aluminium wires/formed wires only

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CLAUSE NO.

TECHNICAL REQUIREMENTS S.No. 11.(b) 12. Type Test Uniformity of zinc coating Adhesion test Remarks For G.S. Formed wires /wires only. For G.S. Formed wires /wires only.

For PVC/XLPE insulation & PVC Sheath 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Test for thickness Tensile strength & elongation tests before ageing and after ageing Ageing in air oven Loss of mass test Hot deformation test Heat shock test Shrinkage test Thermal stability test Hot set test Water absorption test Oxygen index test Smoke density test Acid gas generation test For completed cables 26. Insulation resistance test (Volume resistivity method) High voltage test Flammability test as per IEC - 332 Part-3 (Category -B) For PVC insulation and sheath only For XLPE insulation only For XLPE insulation only For outer sheath only For outer sheath only For outer sheath only For PVC insulation and sheath only For PVC insulation and sheath only For PVC insulation and sheath only

27. 28. 5.01.02

Indicative list of tests / checks, routine and acceptance tests shall be as per quality assurance and inspection table of LT power cables.

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PART - B SUB-SECTION-IIIB-05 CONTROL CABLES

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CONTROL CABLES
1.00.00 1.01.00 CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS: codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes: IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V. Recommended current ratings for cables Low carbon galvanised steel wires, formed wire and tapes for armouring of cables. Methods for random sampling. PVC insulation and sheath of electrical cables. Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics. Test on gases evolved during combustion of electric cables. Standard for type test of Class IE Electric Cables. Tests on Electric cables under fire conditions Part-3 : Tests on bunched wires or cables (category -B) 2.00.00 2.01.00 TECHNICAL REQUIREMENTS The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground burried installation with chances of flooding by water.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-05 CONTROL CABLES

IS : 3961 IS : 3975

IS : 4905 IS : 5831 IS : 8130 IS : 10418 IS : 10810 ASTM-D 2843

ASTM-D-2863

IEC-754 (Part-I) IEEE-383 IEC 332

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CLAUSE NO.

TECHNICAL REQUIREMENTS

2.02.00

Cables shall be armoured. flame retardant, low smoke (FRLS), type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification. Conductor of control cables shall be made of multi stranded, plain annealed copper. PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831. For multicore armoured cables, the armouring shall be of galvanised steel as follows: Calculated nominal dia. of cable under armour 1) 2) Upto 13 mm Above 13 upto 25 mm Size and Type of armour

2.03.00 2.04.00

2.05.00

2.06.00

1.4mm dia GS wire 0.8 mm thick GS formed wire / 1.6 mm dia GS wire 0.8mm thick GS formed wire / 2.0mm dia GS wire 1.4 mm thick GS formed wire/2.5mm dia GS wire 1.4mm thick GS formed wire / 3.15mm dia GS wire 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

3)

Above 25 upto 40 mm

4)

Above 40 upto 55mm

5)

Above 55 upto 70 mm

6)

Above 70mm

The gap between armour wire / formed wire shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface.

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CLAUSE NO.

TECHNICAL REQUIREMENTS

2.07.00

Outer sheath shall be of PVC (grade as applicable) and grey in colour . In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties. (a.) (b.) (c.) Oxygen index of min. 29 (As per ASTMD 2863) Acid gas emission of max. 20% (As per IEC-754-I). Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.

2.08.00

Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following colour scheme shall be adopted. 1 2 3 4 5 core core core core core Red, Black, Yellow or Blue Red & Black Red, Yellow & Blue Red, Yellow, Blue and Black Red, Yellow, Blue, Black and Grey

2.09.00

For cables having more than 5 cores, core identification shall be done by numbering the insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The number shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be of the same colour, which shall contrast with the colour of insulation. The colour of insulation for all the cores shall be grey only. The numerals shall be legible and indelible. The numbers shall be repeated at regular intervals along the core, consecutive numbers being inverted in relation to each other. When the number is a single numeral, a dash shall be placed underneath it. If the number consists of two numerals, these shall be disposed one below the other and a dash placed below the lower numeral. The spacing between consecutive numbers shall not exceed 50 mm. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath: (a.) (b.) (c.) Cable size and voltage grade - To be embossed Word 'FRLS' at every 5 metre - To be embossed Sequential marking of length of the cable in metres at every one metre. To be embossed / printed. -

2.10.00

The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible.

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CLAUSE NO.

TECHNICAL REQUIREMENTS

2.11.00

All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part -3. Allowable tolerances on the overall diameter of the cables shall be +\-2 maximum over the declared value in the technical data sheets. mm

2.12.00

2.13.00

Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable. Cable selection & sizing Control cables shall be sized based on the following considerations: (a) (b) The minimum conductor cross-section shall be 1.5 sq.mm. The minimum number of spare cores in control cables shall be as follows: No. of cores in cable 2C, 3C 5C 7C-12C 14C & above Min. No. of spare cores NIL 1 2 3

2.14.00

2.14.01

Cable lengths shall be considered in such a way that straight through cable joints are avoided. CONSTRUCTIONAL FEATURES 1.1 KV Grade Control Cables shall have stranded copper conductor multicore PVC insulated, PVC inner-sheathed ,armoured / unarmoured, PVC outer-sheathed conforming to IS:1554. (Part-I). 1.1KV grade trailing cables shall have tinned copper (class-5) conductor, insulated with heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding 90 deg C continuous conductor temperature and 250 deg C during short Ckt., inner sheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound conforming to IS 9968. Minimum conductor size shall be 2.5sqmm.

3.00.00 3.01.00

3.02.00

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CLAUSE NO.

TECHNICAL REQUIREMENTS

4.00.00

CABLE DRUMS (a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418. Each drum shall carry manufacturer's name, purchasers name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both the sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

(b.)

5.00.00

TESTS (a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

(b.)

(c.)

(d)

5.01.00 5.01.01

TYPE TESTS The reports for the following type tests shall be submitted for one size of control cables :

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PAGE 5 OF 7

CLAUSE NO.

TECHNICAL REQUIREMENTS

S. No.

Type Test For Conductor

Remarks

1. Annealing test 2. Resistance test

For copper conductor only.

For Armour Wires / Formed Wires 3. Measurement of Dimensions 4. Tensile Test 5. Elongation test 6. Torsion test 7. Wrapping test 8. Resistance test 9(a). Mass of zinc Coating test 9(b). 10. Uniformity of zinc coating Adhesion test For PVC insulation & PVC Sheath 11. Test for thickness 12. Tensile strength and elongation before ageing and after ageing test 13. Ageing in air oven 14. Loss of mass test 15. Hot deformation test 16. Heat shock test 17. Shrinkage test 18. Thermal stability test For PVC insulation and sheath only For PVC insulation and sheath only For PVC insulation and sheath only For PVC insulation and sheath only For GS wires/formed wires only For GS wires/formed wires only For GS wires/formed wires only For round wire only

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CLAUSE NO.

TECHNICAL REQUIREMENTS

19. Oxygen index test 20. Smoke density test 21. Acid gas generation test For completed cables

For outer sheath only For outer sheath only For outer sheath only

22. Insulation resistance test(Volume resistivity method) 23. High voltage test 24. Flammability test as per IEC - 332 Part-3 (Category-B) 5.01.02 Indicative list of tests / checks, routine and acceptance tests shall be as per quality assurance and inspection table of LT power cables.

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PART - B SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

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CLAUSE NO.

TECHNICAL REQUIREMENTS INSTRUMENTATION CABLES

1.00.00 1.01.00 1.01.01

INSTRUMENTATION CABLES GENERAL The Contractor shall supply, erect, terminate and test all instrumentation cables for control and instrumentation equipment/devices/systems included under Contractor's scope. Any other application where it is felt that instrumentation cables are required due to system/operating condition requirements, are also to be provided by Contractor. Other type of cables like fiber optic/co-axial cables for system bus, cables for connection of peripherals etc. (under Contractor's scope) are also to be furnished by the Contractor. Contractor shall supply all cable erection and laying hardware trays, supports, flexible conduits, cable glands, lugs, pull boxes etc. on as required basis for all the systems covered under this specification. Instrumentation Cable Specifications All the instrumentation cables shall be Armoured, twisted, shielded multipair, pre fabricated, flame retardant low smoke (FRLS) type. The Cables shall be provided in non-returnable drums. The drum length shall be 1000m (+/-5%) up to & including 12 pairs and 500 m (+/- 5%) above 12 pairs. Voltage grade of the instrumentation cables shall be 225V (peak value). All instrumentation cables covered in this specification shall comply with VDE 0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475, ANSI MC 96.1, IS-8784, IS-10810 (latest editions) and its amendments read along with this specification. The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-stranded copper for all types of instrumentation cables where as the same shall be min. 1.5sqmm when used in the trailing cables. The insulation of individual conductor shall be extruded PVC meeting the requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of instrumentation cables shall be extruded PVC (compound YM1) as per VDE 0207 Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable shall be provided with marking including manufacturer's name, insulation material, and conductor sizes, no of pairs, voltage ratings, type of cable etc. at intervals not exceeding 625mm. Progressive sequential marking of the length of the cable at
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

1.01.02

1.01.03

1.01.04

1.02.00 1.02.01

1.02.02 1.02.03

1.02.04

1.02.05

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PAGE 1 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS every one meter & progressive markings to read 'FRLS' at every 5 meters shall be provided on the outer sheath of all instrumentation cables. The colour of outer sheath shall be sky blue. Fillers in multiple conductor cables shall be flame retardant and moisture resistant. Cable accessories such as harnessing components, markers, bedding, cable jointer, binding tape etc. shall also have flame retardant quality.

1.02.06

All instrumentation cables shall be provided with overall shielding. However, multipair cables carrying analog signals shall be provided with individual pair shielding in addition to overall shielding. Shielding shall be of Aluminium-Mylar tape with 100% coverage and with atleast 20% overlapping. The thickness of individual pair shield shall be 28 micron (minimum) and that of overall shield shall be 55 microns (minimum). Separate drain wires for individual pair shield (wherever applicable) as well as overall shield shall be provided. Drain wire shall be of seven (7) strand 20 AWG (0.51 Sq.mm) tin coated copper conductor. Maximum lay of individual twisted pair shall be 50 mm. Bidder to ensure that individual core diameter shall be suitable for maxi-termi connection. Insulation thickness of individual core shall be between 0.28 and 0.35 mm for 0.5 mm2 cables. The outer sheath of the instrumentation cables shall meet the following minimum requirements: (i) An Oxygen index of not less than 29% and a Temperature index of not less than 250 deg.C as per ASTMD-2863. Maximum acid gas generation by weight as per IEC-754-I shall not be more than 20%. Smoke Density Rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843. The results of smoke density test shall be plotted on a curve indicating light absorption vs. time as per ASTMD2843. The average area under the curve (smoke density rating) shall not be more than 60%. Complete cable assembly shall pass Swedish Chimney test as per SEN4241475 and flammability test as per IEEE-383.

1.02.07

(ii)

(iii)

(iv)

The thickness of outer sheath shall be as per the guidelines given in VDE 0816. Thickness of outer sheath shall not be less than 1.8 mm in any case. Allowable tolerance of overall diameter of the cables shall be +/-2 mm max. over the declared value in technical data sheets. The variation in diameter and the ovality at any cross section shall not be more than 1.0 mm. 1.02.08 All instrumentation cables shall be suitable for continuous operation at 70 deg.C, except for high temperature resistant teflon insulated cables which shall be suitable
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 2 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS for continuous operation at 205 deg.C. The cables shall be suitable for laying in wet or dry locations in trays, conduits, ducts, trenches and under ground buried installations.

1.02.09

The thermocouple extension cables shall be of single/multi pair, twisted & shielded, PVC insulated, FRLS PVC sheathed and compatible for the type of thermocouples employed. The material of conductor shall be as per ANSI MC-96.1. The material and requirements of conductor insulation, shielding and outer sheath shall be as per the above clauses. Cable parameters such as mutual capacitance between conductors, conductor resistance, insulation resistance, characteristic impedance, cross talk and attenuation figures at 20 deg.C ( 3 deg.C) for various types of cables as applicable shall be as specified under Table A. Identification of the cores & pairs shall be done with suitable colour coding & band marking as well as by numbering of cores/pairs as per VDE: 0815. The details of colour coding etc. shall be as approved by Employer during detailed stage. Also refer Table B for description of various type of cables. The Contractor shall furnish all documentary evidence including cross-sectional drgs, test certificates to substantiate the suitability of cables offered for different applications. The contractor shall also clearly bring out the application wise details for each type of cable offered. All prefabricated cables shall have 10% spare cores which will not be connected to pin connectors. CABLE PARAMETER Table A : CABLE PARAMETER Conductor Size Parameter/ Type of Cable Individual and overall shielded (Type F) 0.5 Sq.mm. Overall Shielded(Type-G) Compensating cables (with/without Teflon coating) (Type A,B,C) 200 nF/Km

1.02.10

1.02.11

1.02.12

1.02.13 1.02.14

Mutual capacitance at 0.8 kHz (max.) Conductor Resistance (max.)

120 nF/Km.

100 nF/Km.

73.4 ohm/km (loop)For Type F

73.4 ohm/km (loop)

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SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 3 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

Insulation resistance Cross-Talk figure at 0.8 kHz (min.) Characteristic impedance (max.) Attenuation at 1 kHz (max.) 1.02.15

100 M ohm/ Km

100 M ohm/ Km

100 M ohm/ Km

60 dB

60 dB

60 dB

320 ohm

340 ohm

1.2 dB/Km

1.2 dB/Km

DESCRIPTION OF VARIOUS TYPE OF CABLES TABLE B Type Conductor Size 0.5 mm2 0.5 mm2 0.5 mm2 Description

Two pair shielded and twisted pair T/C extension cable, ANSI type KX, stranded conductor. Two pair shielded & twisted T/C extension cable ANSI type SX, stranded conductor. Two pair shielded & twisted heat resistant teflon insulation & Outer sheath T/C extension cable ANSI type KX, stranded conductor. Multi pair individual pair & overall shielded twisted pair instrumentation cable (4/8/12/24 pair) for analog signals with stranded copper conductor. Multi pair overall shielded & twisted pair instrumentation cable (2/4/8/12/24/48 pair) for binary signals with stranded copper conductor. Type F cable/type G cable with heat resistant teflon insulation & outer-sheath for high temperature application. Multi core/ Multi pair shielded cable for system specific cables. Like conductivity type level switches, Vibration monitoring system cable , System Bus cable, Bus communications cable etc. as applicable.

0.5 mm2

0.5 mm2

0.5 mm2

As per specific Standard/ Requirement for each application

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SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 4 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS INSTRUMENTATION PHILOSOPHY CABLE INTERCONNECTION AND TERMINATION

1.03.00 1.03.01

The cable interconnection philosophy to be adopted shall be such that extensive grouping of signals by large scale use of field mounted Group JBs at strategic locations (where large concentration of signals are available, e.g. switchgear) is done and consequently cable with higher number of pairs are extensively used. The details of termination to be followed are mentioned in the given table C. TABLE C:- CABLE TERMINATION TO BE FOLLOWED Application Type Of Termination Type Of Cable

FROM (A) Valves/dampers drives (Integral Junction box)

TO (B) Marshalling ubicle/local group JB/Termination/Control Cabinets/System Cabinets Local junction box

END A Plug in connector

END B Post moun ted Maxi termi/cage clamp type. G

RTD heads

Plug in connector

Maxitermi/ cage clamp (Rail moun ted) type. Screwed/ Cage clamp Type Screwed/ Cage clamp Type Post moun ted Maxi termi/cage clamp type.

Thermocouples

CJC box

Plug in connector

A,B,C*

RTD thermocouple

Temperature transmitter

Plug in connector

Local Junction box, CJC box, Group JB/ MCC/SWGR

Marshalling Cubicle/local group JB/Termination/ Control Cabinets/System Cabinets

Maxitermi/ cage clamp (Rail moun ted) type.

F,G

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TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 5 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

Local Junction box, MCC/SWGR

Group JB

Maxitermi/ cage clamp (Rail moun ted) type. Maxitermi/ cage clamp (Rail moun ted) type. Post mounted Maxi termi/cage clamp type. Post moun ted Maxi termi/cage clamp type.

Maxitermi/ cage clamp (Rail moun ted) type. Maxitermi/c age clamp (Rail moun ted) type. Post mounted Maxi termi/cage clamp type. Plug in connector/ Cage clamp type (rail mounted). Plug in connector

F,G

Field mounted Instrument

Group JB

F,G

Marshalling cubicle/ Termination Cabinet

Electronic system cabinet

F,G

Marshalling / Termination system cabinets

UCP mounted equipments

F,G (with plug-in connector at one end)

DDCMIS/PLC cabinets Notes

PC, Printers etc.

Plug in connector

Mfr.s Standard

Normally 10% spare core shall be provided when the number of pairs of cables are more than four pairs. For analog signals individual pair shielding & overall shielding & for Binary signals only overall shielding of instrumentation cables shall be provided. * For high temperature application only.

2.00.00 2.01.00

TERMINAL BLOCKS All terminal blocks shall be rail mounted/post mounted, cage clamp type/maxi-termi type (MTP) with high quality non-flammable insulating material of melamine suitable for working temperature of 105 deg. C. The terminal blocks in field mounted junction boxes, CJC boxes, etc., shall be suitable for cage clamp/ MTP connections. The terminal blocks in Control Equipment Room logic/termination/marshalling cubicles shall be suitable for post mounted maxi-termi/cage clamp connection at the field input end. The terminal blocks for DDCMIS input/output connections from/to SWGR/MCC, Actuators with Integral Starter (for coupling relays and check back signals of 11 kV and 3.3 kV auxiliaries, LT drives/valves & dampers/solenoids, CT &
SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

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PAGE 6 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS VT, etc.) shall be provided with built in test and disconnect facilities complete with plug, slide clamp, test socket, etc. The exact type of terminal blocks to be provided by the Contractor and the technical details of the same including width etc. shall be subject to Employer's approval.

2.02.00

All the terminal blocks shall be provided complete with all required accessories including assembly rail, locking pin and section, end brackets, partitions, small partitions, test plug bolts and test plug (as specified above for SWGR connections) transparent covers, support brackets, distance sleeves, warning label, marking, etc. The marking on terminal strips shall correspond to the terminal numbering on wiring diagrams. At least 20% spare unused terminals shall be provided everywhere including local junction boxes, instrument racks/enclosures, termination/marshalling cabinets, etc. All terminal blocks shall be numbered for identification and grouped according to the function. Engraved labels shall be provided on the terminal blocks. The terminal blocks shall be arranged with atleast 100 mm clearance between two sets of terminal blocks and between terminal blocks and junction box walls. For ensuring proper connections, Contractor shall provide suitable accessories, along with insulation sleeves. The exact connecting accessory shall be finalised as per application during detail engineering stage subject to Employer's approval without any cost repercussions. Internal wiring in factory prewired electronic equipment cabinets may be installed according to the Contractor's standard as to wire size and method of termination or internal equipment. Terminal blocks for connection of external circuits into factory prewired electronic equipment cabinets shall meet all the requirements as specified above. INTERNAL PANELS/CABINETS/SYSTEM CABINETS WIRING Internal panel/cabinet wiring shall be of multistranded copper conductor with FRLS PVC insulation without shield and outer sheath meeting the requirements of VDE 0815. Wiring to door mounted devices shall be done by 19 strand copper wire provided with adequate loop lengths of hinge wire so that multiple door opening shall not cause fatigue breaking of the conductor. All internal wires shall be provided with tag and identification nos. etched on tightly fitted ferules at both ends in Employer's approved format. All wires directly connected to trip devices shall be distinguished by one additional red colour ferrule. All external connection shall be made with one wire per termination point. Wires shall not be tapped or spliced between terminal points.

2.03.00

2.04.00

2.05.00

2.06.00

3.00.00 3.01.00

3.02.00

3.03.00

3.04.00

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PAGE 7 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS All floor slots of desk/panels/cabinets used for cable entrance shall be provided with removable gasketed gland plates and sealing material. Split type grommets shall be used for prefabricated cables. All the special tools as may be required for solderless connections shall be provided by Bidder. Wire sizes to be utilised for internal wiring. (i) (ii) Current (4-20 mA), low voltage signals (48V) Power supply and internal illumination. 0.5 Sq.mm. 2.5Sq.mm. minimum (shall be as per load requirement.)

3.05.00

3.06.00

3.07.00

4.00.00 4.01.00

CABLE INSTALLATION AND ROUTING All cables assigned to a particular duct/conduit shall be grouped and pulled in simultaneously using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be reused without approval of Employer. Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack.

4.02.00

Cables shall terminate in the enclosure through cable glands. All cable glands shall be properly gasketed. All cables shall be identified by tag. Nos. provided in Employer's approved format at both the ends as well as at an interval of 5 meters. Line voltage drop due to high resistance splices, terminal contacts, insulation resistance at terminal block, very long transmission line etc. shall be reduced as far as practicable. The cables emanating from redundant equipment/devices shall be routed through different routes. CABLE LAYING AND ACCESSORIES CABLE LAYING 1 2 Cables shall be laid strictly in line with cable schedule. Identification tags for cables. Indelible tags to be provided at all terminations, on both sides of wall or

4.03.00

4.04.00

4.05.00

5.00.00 5.01.00

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SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 8 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable trench/tray. 3 Cable tray numbering and marking. To be provided at every 10m and at each end of cable way & branch connection. 4 5 Joints for less than 250 Meters run of cable shall not be permitted. Buried cable protection With concrete slabs; Route markers at every 20 Meters along the route & at every bend. 6 Road Crossings Cables to pass through burried high density PE pipes encased in PCC. At least 300 mm clearance shall be provided between HT power & LT power cables, LT power & LT control/instrumentation cables,

Spacing between cables of same voltage grade shall be in accordance with the derating criteria adopted for cable sizing. 7 Segregation (physical isolation to prevent fire jumping) a All cable associated with the unit shall be segregated from cables of other Units. Interplant cables of station auxiliaries and unit critical drives shall be segregated in such a way that not more than half of the drives are lost in case of single incident of fire.

Cable clamping All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the tray. For cables in trefoil formation, trefoil clamps shall be provided.

6.00.00

FIELD MOUNTED LOCAL JUNCTION BOXES (i) No. of ways 12/24/36/48/64/72/96/128 with 20% spare terminals.

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SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 9 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS (ii) Material and 4mm thick fiberglass reinforced polyester. Thickness Type Screwed at all four corners for door. Door handle shall be self locking with common key. Door gasket shall be of synthetic rubber.

(iii)

(iv)

Mounting Suitable for mounting on walls, columns, structures etc. clamps and The brackets, bolts, nuts, screws, glands and lugs accessories required for erection shall be of corrosion resistant material, included in Bidders scope of supply. Type of terminal blocks Rail mounted maxitermi or cage-clamp type suitable for conductor size upto 2.5 mm2. A M6 earthing stud shall be provided. IP:55 minimum for Indoor & IP-65 Outdoor applications

(v)

(vi)

Protection Class Colour

(vii)

To be decided during detailed engineering & subject to Employers approval.

7.00.00 7.01.00

CONDUITS All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The conduit interior and exterior surfaces shall have continuous zinc coating with an overcoat of transparent enamel lacker or zinc chromate. Flexible conduit shall be heat resistant lead coated steel, water leak, fire and rust proof. The temperature rating of flexible conduit shall be suitable for actual application. TESTS GENERAL (a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the

8.00.00 8.01.00

(b.)

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SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 10 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. (c.) All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

(d)

8.02.00 8.02.01

TYPE TEST Following type tests reports shall be submitted for one size of each type of instrumentation cables: For Conductor (including Drain Wire) Sl. No. 1. 2. 3. Test Reference Standard Remarks

8.02.02

Resistance Test Diameter Tin coating (Persulphate Test)

VDE:0815 IS:10810 test* As per standard

relevant *Applicable wire only

for

drain

8.02.03

For PVC Insulation And PVC Sheath Sl. No . 1. 2. Test Reference Standard IS:10810 test VDE:0472 Remarks

Test for thickness** Tensile strength and elongation before and after ageing** Ageing in air ovens** Loss of Mass Test Hot deformation test

3. 4. 5.

- do-do-do-

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SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES

PAGE 11 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS 6. 7. 8. 9. 10. 11. 12. 13. 14. Heat shock test Shrinkage test** Cold bend/ cold impact test Colour fastness to water Thermal stability test Bleeding and blooming Oxygen index test (for sheath & fillers) Smoke density test (for sheath & fillers) - do-do- do-do-do-doASTMD-2863 ASTMD-2843

Acid gas generation test (for sheath & IEC-754-1 fillers)

8.02.04

For Al-Mylar Shield Sl.No. 1. 2. 3. 4. Test Continuity test Shield thickness test Overlap test Noise test Reference Standard As per relevant standard -do-do Remarks

interference IEEE-Transaction March'67

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PAGE 12 OF 12

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PART - B SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS ILLUMINATION

1.00.00 1.01.00

GENERAL This specification covers the general description of design, manufacture and construction features, testing, supply, installation and commissioning of the illumination system equipment required to be provided by the bidder. CODES AND STANDARDS All standards and codes of practice referred to herein shall be the latest edition including all applicable official amendments & revisions as on date of bid opening. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards & codes. Lighting Fixtures and Accessories IS:1913 IS:2148 IS:418 IS:1258 IS:1534 IS:1569 General and safety requirements for luminaries. Flame proof enclosures of electrical apparatus. Tungsten filament general service electric lamps. Bayonet lamp holders. Ballast for fluorescent lamps. Capacitors for use in tubular fluorescent, high pressure mercury vapour and low pressure sodium vapour discharge lamp circuit. Industrial luminaire with metal reflectors. Luminaire for Street lighting. Starters for fluorescent lamps. Tubular fluorescent lamps for general lighting services. Bi-pin lamp holders for tubular fluorescent lamps. Holders for starters for tubular fluorescent lamps. Dust-tight electric lighting fittings. Ballasts for high pressure mercury vapour lamps.

1.02.00 1.03.00

1.04.00

IS:1777 IS:2149 IS:2215 IS:2418 IS:3323 IS:3324 IS:4013 IS:6616

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PAGE 1 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

IS:8224 IS:9900 IS:9974 IS:10276 IS:10322 IS:13021 1.05.00

Electric Lighting fittings for Division 2 areas. High-pressure mercury vapour lamps. High pressure Sodium vapour lamps. Edison screw lamp holders. Luminaires. AC Supplied Electronic Ballasts for tubular fluorescent lamps.

Lighting Panels, Switch-boxes, Receptacles and Junction Boxes IS:2147 Degree of protection provided by enclosures for low-voltage switchgear and control gear. Plugs & socket outlets of rated voltage upto and Including 250volts & rated current upto and including 16 Amps. Danger notice plates. Low voltage switchgear and controlgear Switches for domestic and similar purposes. Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto and including 1000 V AC and 1200 V DC. Low voltage fuses for voltages not exceeding 1000V AC or 1500 V DC.

IS:1293

IS:2551 IS:13947 IS:3854 IS:6875

IS:13703

1.06.00

Conduits, Pipes and Accessories IS:2667 IS:3837 IS:9537 Fittings for rigid steel conduit for electrical wiring. Accessories for rigid steel conduits for electrical wiring. Conduits for electrical installations.

1.07.00

Lighting Wires/Cables IS:694 PVC insulated cables for working voltages upto and including 1100 V Recommended current ratings for cables. (PVC Insulated and PVC sheathed heavy duty cables and light duty cables).

IS:3961

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PAGE 2 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

IS:8130 IS:10810 1.08.00

Conductors for insulated electric cables and flexible cords. Methods of tests for cables.

Electrical Installation Practices & Miscellaneous IS:1944 IS:3646 IS:5572 Code of practice for lighting of public thorough fare Code of practice for interior illumination. Classification of Hazardous areas (other than Mines)having flammable gases and Vapours for electrical installation Code of practice for industrial lighting. National Electrical Code Indian Electricity Rules. Indian Electricity Act IS:5 IS:280 IS:374 IS:732 IS:1255 Colour for ready mixed paints & enamels. Mild steel wires for general engineering purposes. Electric ceiling type fans & regulators. Code of practice for electrical wiring installations. Code of practice for installation and maintenance of power cables Upto and including 33KV rating. Steel for general structural purposes Recommended practice for hot-dip galvanizing of iron and steel. Methods for testing uniformity of coating of zinc coated articles. Tubular steel poles for overhead power lines. Code of practice for earthing Guide for safety procedures and practices in electrical work. Guide for selection of electrical equipments for hazardous areas. Mechanical cable glands

IS:6665

IS:2062 IS:2629 IS:2633 IS:2713 IS:3043 IS:5216 IS:5571 BS:6121

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 3 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS LIGHTING SYSTEM DESCRIPTION Normal AC Lighting System Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels (LPs) which will be fed from the lighting distribution boards (LDBs) which in turn will be fed from LT MCCs.

2.00.00 2.01.00

2.02.00

DC Lighting System Emergency DC lighting is to be provided through self contained DC emergency fixture at strategic locations. The fixtures shall be switched ON automatically in case of failure of AC supply.

2.03.00

DESIGN PHILOSOPHY 1. 2. A comprehensive illumination system shall be provided. All lighting system shall be automatically controlled by synchronous timer. Provision to bypass the timer shall be provided in the panel for manual control. The system shall include distribution boards, lighting panels, lighting fixtures, junction boxes, receptacles, switch boards, lighting pole/masts, conduits, cables and wires, etc. The system shall cover all interior and exterior lighting such as area lighting, including Transformer yard etc. The constructional features of lighting distribution boards shall be similar to AC/DC distribution boards described in chapter of LT Switchgear. Outgoing circuits in LPs shall be provided with MCBs of adequate ratings. The illumination system shall be designed on the basis of best engineering practice and shall ensure uniform, reliable, aesthetically pleasing and glare free illumination. The lighting fixtures shall be designed for minimum glare. The design shall prevent glare/luminous patch seen on VDU/ Large video screens, when viewed from an angle. The finish of the fixtures shall be such that no bright spots are produced either by direct light source or by reflection. The diffusers/ louvers used in fluorescent fixtures shall be made of impact resistant polystyrene sheet and shall have no yellowing property over a prolonged period. The Lux levels to be adopted for various area are indicated at Annexure A. Apart from maintenance factor as given below, Temperature correction factor shall be considered in the lighting design for fluorescent fixtures located in non air conditioned area.

3.

4.

5.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 4 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

(a) (b.) (c.) 6. 7. 8.

Air conditioned area Non Air conditioned and other indoor area Dust prone indoor areas and outdoor areas

: 0.8 : 0.7 : 0.6

All outdoor fixtures shall be weather proof. All lighting fixtures & control gears shall be powder coated. Wires of different phase shall normally run in separate conduit. For areas illuminated by more than one circuit, the adjacent circuits shall be from different phases. Power supply shall be fed from suitable number of conveniently located lighting distribution boards (LDB) and lighting panels (LP). AC lighting supply shall be isolated from main supply by isolation transformers (415/433V, delta / star, epoxy insulated, air cooled, dry type) of max. rating of 100KVA and fault level restricted to 3 KA at Lighting Panels. Minimum 2 ways shall be kept as spare feeders in the lighting panels. Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel. The door shall be hinged and the panel shall be gasketted to achieve specified degree of protection. The panel shall be provided with terminal bocks for incoming and outgoing circuits, earthing terminals, removable gland plates at bottom and canopy shall be provided with slope towards the rear side of the panel. Wiring inside the panel shall be carried out with 1100 V grade PVC insulated stranded copper wires of adequate size. Terminal blocks shall be 750 V grade, clip-on stud type, moulded in melamine and shrouded. All MCBs/ Isolators/ Switches/ Contactors etc. shall be mounted inside the panel and a fibre glass sheet shall be provided inside the main door such that the operating knobs of MCBs etc., shall project out of it for safe operation against accidental contact. MCBs shall be current limiting type with magnetic and thermal release suitable for manual closing and automatic tripping under fault condition with short circuit interrupting capacity of 9 KA rms. Isolators of AC lighting panels shall be of TPN, continuous duty, load make-break type and fuses shall be of HRC plug in type. Synchronous timers shall be quartz controlled electronic type, complete with rechargeable nickel cadmium cell, 24 hours range day dial, NO/NC contacts etc. and suitable for operation on 240V AC supply. The exterior side of panel, shall be powder coated with smoke grey, shade RAL9002 and the interior side of panel, shall be white.

9.

10.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 5 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS Lighting panels shall have IP55 degree of protection in general. However LP located in dusty areas shall have IP65 degree of protection. Ladder approaches shall be provided for maintaining the fixtures wherever applicable. 11. 20A, 240V AC industrial type receptacles shall be provided in the areas : Two in each switchgear / MCC room and Pump house These receptacles shall be energized from lighting panel. Maximum three receptacles shall be connected in one circuit. All fluorescent fixtures shall have energy efficient T5 type fluorescent lamps except those in div 2 hazardous area. The louvers of these fixtures shall be designed for T5 type fluorescent lamps. All fluorescent lamps shall have cool day light colour designation. The mirror optics type fluorescent fixtures shall have no iridescence effect. following

12.

2.03.00 2.03.01

Ballasts All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts. All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (DivII/Hazardous Area) shall be provided with electronic ballasts. All luminaires and their accessories and components shall be of type readily replaceable by available Indian makes. Fans & Regulator Ceiling Fans, to be provided in non air-conditioned office / control room area shall be suitable for operation on 240 V, 50 Hz, AC supply comprising of class F insulated copper wound single phase motor, 1200mm sweep, aerodynamically designed well balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enameled white. Power factor of fans shall not be less than 0.9. Each fan shall cover approximately 10sq.m. area. Switch Box Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative, perspex cover. Switchbox shall be hot dip galvanised Junction boxes Junction box for lighting fixtures shall be deep drawn or fabricated type made of min. 1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised .

2.04.00

2.05.00 2.05.01

2.06.00 2.06.01

2.07.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 6 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS Conduits, Fittings & Accessories Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal area and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive area shall be offered. Alternatively glass reinforced epoxy conduits with comparable compressive and impact strength with that of heavy duty steel conduits may be offered.

2.08.00

2.08.01

Rigid Steel Conduits (a.) Rigid steel conduits shall be heavy duty type,hot dip galvanised conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded on both sides and threaded length shall be protected by zinc rich paint. Conduits shall be smooth from inside and outside.

2.08.02 2.08.03

Flexible Steel Conduits Flexible conduit shall be water proof and rust proof made of heat resistant lead coated steel. Pull-out Boxes Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc.. Pullout boxes shall have cover with screw and shall be provided with good quality gasket lining. Pull out boxes shall be weather proof type suitable for IP :55 degree of protection. Pull out box & its cover shall be hot dip galvanised. Lighting Wires Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded copper/aluminium wire for fixed wiring installation. colour of the PVC insulation of wires shall be Red, Yellow, Blue and Black for R,Y,B phases & neutral, respectively and white & grey for DC positive & DC negative circuits, respectively. Minimum size of wire shall not be less than 1.5.sq.mm. for copper and 4 sq.mm. for aluminium. The size of the lighting wires/ cables shall be selected such that the total voltage drop from the LDB to the lighting fixture / receptacle does not exceed 3%. Lighting Poles The poles wherever required shall be of ERW tubes of specified lengths, stepped tubular or swaged tubular and joined together. Lighting poles shall be painted with two coats of red Oxide and Zinc chromate in Synthetic compound primer on the exposed outside surface and with Bituminous paint all along the inside of the pole and outside portion which shall be embedded in foundation at manufacturing stage.

2.08.04 2.09.00

2.10.00 2.10.01

2.11.00 2.11.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 7 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS Lighting Masts Lighting Masts shall be of continuously tapered polygonal cross section hot dip galvanised presenting a pleasing appearance. The Mast shall be of 30M height with lantern carriage to enable raising / lowering for ease of maintenance, including the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built power tool, luminaries, suitable aviation warning light, lightning along with necessary power cables within the mast. The mast shall be delivered only in three sections & shall be joined together by slip stressed fit method at site. No site welding or bolted joints shall be done on the mast. Lighting fixtures shall generally be group controlled directly from lighting panel. However, in office areas, control shall be provided through switch boxes. Each switch shall control a maximum of three fluorescent fixtures. Wiring shall run throughout in separate conduits. Wires of different phases shall run in different conduits. Wiring for lighting circuits and receptacle circuits shall be carried out in separate conduits and from separate feeders. Lighting panels etc. shall be earthed by two separate and distinct connections with earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase receptacles etc. shall be earthed by means of separate earth continuity conductor. The earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit run. Cable armours shall be connected to earthing system at both the ends. TESTS All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. Selection of samples for acceptance test & routine test and acceptance criteria for all the items shall be as per relevant I.S Acceptance Test and Routine Test All lighting fixtures, lamps and other items shall be subjected to acceptance and routine test, as per relevant specified standards. Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to physical and dimensional checks. Galvanizing Tests The quality of galvanizing shall be smooth, continuous, free from flux stains and shall be inspected visually.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

2.12.00 2.12.01

2.13.00

2.14.00

2.15.00

3.00.00 3.01.00

3.02.00

3.03.00 3.03.01

3.03.02

3.04.00 3.04.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 8 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS In addition following tests shall be conducted as acceptance tests. (a.) Uniformity of coating - The coating of any article shall withstand four 1minute dips in standard copper sulphate solution without the formation of an adherent red spot of metallic copper upon the basic metal. The quality of cadmium/zinc plating on items with screw threads shall be free from visible defects such as unplated areas, blisters and modules and shall be inspected visually. In addition, the plating thickness shall be determined microscopically/ chemically or electronically.

3.04.02

(b.)

(c.)

4.00.00

COMMISSIONING CHECKS 1. On completion of installation work, the Contractor shall request the Project manager for inspection and test with minimum of fourteen (14) days advance notice. The Project manager shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Contractor. The installation shall be then tested and commissioned in presence of the Project manager. The contractor shall provide all, men material and equipment required to carry out the tests. All rectifications, repair or adjustment work found necessary during inspection, testing and commissioning shall be carried out by the Contractor without any extra cost. The handing over the lighting installation shall be effected only after the receipt of written instruction from the Employer/his authorized representative. The testing shall be done in accordance with the applicable Indian Standards and codes of practices. The following tests shall be specifically carried out for all lighting installation. (a) (b) (c) (d) Insulation Resistance. Testing of earth continuity path. Polarity test of single phase switches. Functional checks.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

2.

3.

4.

5.

6.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 9 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS 7. The lighting circuits shall be tested in the following manner : (a) All switches ON and consuming devices in circuit, both poles connected together to obtain resistance to earth. Insulation resistance between poles with lamps and other consuming devices removed and switches ON.

(b)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 10 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

ANNEXURE-A Sl No. Location Average Illumination Level(Lux) rooms 200 Type of Fixture

(a)

Switchgear

Industrial trough type fluorescent Mirror optics with anti-glare features

(b)

Control room, computer room, control equipment room

300

(c)

Offices, conference 300 rooms,etc. Battery rooms 100

Decorative mirror optics type

(d)

Totally enclosed corrosion proof HPSV flood light

(e)

Transformer

yard 10(general) 50(on equipment) 150

(f)

Diesel generating room, Compressor room, pump house etc.

HPSV medium bay/Industrial trough type fluorescent

(g)

Fuel oil pump house 150

Flame proof fluorescent fixtures suitable for division-2 hazardous area Industrial trough type fluorescent

(h)

Cable galleries

50

(i)

Street lightingprimary roads secondary roads 20 10 20 HPSV street lights Degree of Protection IP54 HPSV flood light

(j)

Outdoor storage handlingand unloading area

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 11 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

(k)

DM plant,water treatment plant

150

Industrial trough type/corrosion proof fluorescent Corrosion proof fluorescent Industrial trough type/HPSV Industrial trough type fluorescent

(l) (m) (n)

Chemical stores Permanent stores Workshop.general work bench Laboratory General Analysis area

150 150 150

(o)

150 300

Mirror optics fluorescent Corrosion resistant, fluorescent 50 Industrial trough type fluorescent HPSV flood light

(p)

Garage/Car Parking

(q)

Switchyard and all outdoor areas

20(general 50(on strategic equipment) 300

(r)

Stone picking area

HPSV dust tight well glass fixture (flood light type) HPSV dust tight medium bay or well glass fixture.

(s)

Transfer points, crusher house, track hopper, track hopper shed, tunnels, bunker house. Conveyor galleries

100

(t)

70

HPSV dust tight well glass fixture. Min. one landing. fixture at every

(u)

Stair cases

100

NOTE:- Any additional fixtures required to take care of the dark patches / shadows shall also be provided.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-07 ILLUMINATION SYSTEM

PAGE 12 OF 12

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CAD nLE NAIIE : SIAilD-2O0-6O-DI

PART - B SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CABLING, EARTHING & LIGHTNING PROTECTION 1.00.00 1.01.00 CODES AND STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards, etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards/ codes as applicable. IS:513 IS:802 IS:1079 IS:1239 IS:1255 IS:1367 Part-13 IS:13947 IS:2309 IS:2629 IS:2633 IS:3043 IS:3063 IS:6745 IS:8308 IS:8309 IS:9537 IS:9595 Cold rolled low carbon steel sheets and strips. Code of practice for the use of Structural Steel in Overhead Transmission Line Towers. Hot Rolled carbon steel sheet & strips Mild steel tubes, tubular and other wrought steel fittings Code of practice for installation and maintenance of power cables upto and including 33 KV rating Technical supply conditions for threaded Steel fasteners. (Hot dip galvanized coatings on threaded fasteners). Degree of protection provided by enclosures for low voltage switchgear and control gear Code of Practice for the protection of building and allied structures against lightning. Recommended practice for hot dip galvanising of iron & steel Method for testing uniformity of coating on zinc coated articles. Code of practice for Earthing Fasteners single coil rectangular section spring washers. Methods for determination of mass of zinc coating on zinc coated iron & steel articles. Compression type tubular in- line connectors for aluminium conductors of insulated cables Compression type tubular terminal conductors of insulated cables. Conduits for electrical installation. Metal arc welding of carbon and carbon manganese steels recommendations. ends for aluminium

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

PAGE 1 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

IS:13573

Joints and terminations for polymeric cables for working voltages from 6.6kv upto and including 33kv performance requirements and type tests. Fire tests on building materials and structures IEEE guide for safety in AC substation grounding Grounding of Industrial & commercial power systems Non tension proof compression joints for Aluminium conductors. Cable lugs for compression connections, ring Aluminium conductors Tests on cable terminations and straight through joints Specification for mechanical Cable glands for elastomers and plastic insulated cables. Indian Electricity Act. Indian Electricity Rules. type ,for

BS:476 IEEE:80 IEEE:142 DIN 46267 (Part-II) DIN 46329 VDE 0278 BS:6121

1.02.00

Equipment complying with other internationally accepted standards such as IEC, BS, DIN, USA, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. DESIGN AND CONSTRUCTIONAL FEATURE Transformer yard and Switchyard In transformer yard and switchyard area, cables shall be laid in RCC concrete trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for Rail/road crossing it shall be as per rail/road crossing norms. False floors are not to be provided for cabling purpose. Cable entry Cable entry from outdoor underground/cable routes to the buildings, if any, shall be above the finished floor level of the building to avoid water entry in to the room through the trenches.

2.00.00 2.01.00 2.01.01

2.01.02 2.01.03

2.01.04

Trenches PCC flooring of built up trenches shall be sloped for effective drainage with sump pits and sump pumps.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

PAGE 2 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Interplant cabling for main routes shall be laid along overhead trestles/duct banks. However, from tap-offs, same can be through shallow trenches with approval of Employer. In case of Duct banks , pull-pits shall be filled with sand and provided with a PCC covering. Directly buried cables, if essential ,shall not have concentration of more than 4 cables in one route. For overhead trestles, the bottom of the steel supporting structure shall be generally at 3.0M above the grade level except for rail/road crossings where it shall be at 8.0M above grade level. Cable trenches shall be provided only in Switchgear/MCC rooms. EQUIPMENT DESCRIPTION Cable trays, Fittings & Accessories Cable trays shall be ladder/perforated type as specified complete with matching fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required. Cable trays, fittings and accessories shall be fabricated out of rolled mild steel sheets free from flaws such as laminations, rolling marks, pitting etc. These (including hardware) shall be hot dip galvanized as per relevant IS. Cable trays shall be ladder type for power/control cables and shall be perforated type for instrumentation cables. Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall be minimum 3 mm. Typical details of cable trays, fittings and accessories are shown in the enclosed drawings Cable troughs shall be required for branching out few cables from main cable route. These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm SUPPORT SYSTEM FOR CABLE TRAYS Cable tray support system shall be pre-fabricated similar or equivalent to "Unistrut make. Support system for cable trays shall essentially comprise of the two components i.e. main support channel and cantilever arms. The main support channel shall be of two types: (i) C1:- having provision of supporting cable trays on one side and (ii) C2:having provision of supporting cable trays on both sides. The support system shall be the type described hereunder a. Cable supporting steel work for cable racks/cables shall comprise of various channel sections, cantilever arms, various brackets, clamps, floor plates, all hardware such as lock washers, hexagon nuts, hexagon head bolt, support hooks, stud nuts, hexagon head screw, channel nut, channel nut with springs, fixing studs, etc.

2.01.05

2.01.06 3.00.00 3.01.00 3.01.01

3.01.02

3.01.03

3.01.04

3.02.00 3.02.01 3.02.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

PAGE 3 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

b.

The system shall be designed such that it allows easy assembly at site by using bolting. All cable supporting steel work, hardware fittings and accessories shall be prefabricated factory galvanised. The main support and cantilever arms shall be fixed at site using necessary brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various arrangements required to support the cable trays. Welding of the components shall not be allowed. However, welding of the bracket (to which the main support channel is bolted) to the overhead beams, structural steel, insert plates or reinforcement bars will be permitted. Any cutting or welding of the galvanised surface shall be brushed and red lead primer, oil primer & aluminium paint shall be applied. All steel components, accessories, fittings and hardware shall be hot dip galvanised after completing welding, cutting, drilling and other machining operation. The typical arrangement of flexible support system is shown in the enclosed drawings and described briefly below: The main support channel and cantilever arms shall be fabricated out of minimum 2.5 thick rolled steel sheet conforming to IS.

c.

d.

e.

f.

Cantilever arms of 300 mm, 600 mm and 750 mm in length are required, and shall be as shown in the enclosed drawing. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position.

3.02.03

The size of structural steel members or thickness of sheet steel of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Main support channels may be supplied in any suitable lengths to minimise the wastage. Nevertheless, the support system shall be designed by the bidder to fully meet the requirements of type tests as specified. In case the system fails in the tests, the components design modification shall be done by the Bidder without any additional cost to the Employer. Pipes, Fittings & Accessories Pipes offered shall be complete with fittings and accessories (like tees, elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The size of the pipe shall be selected on the basis of maximum 40% fill criteria GI Pipes shall be of medium duty as per IS:1239 Junction Boxes Junction Boxes shall be made of Fire retardant material. Material of JB shall be thermoplastic or thermosetting or FRP type. The box shall be provided with the
SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

3.03.00 3.03.01

3.03.02 3.04.00 3.04.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 4 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS terminal blocks, mounting bracket and screws etc. the cable entry shall be through galvanized steel conduits of 20 mm diameter. The JB shall have suitable for installing glands of suitable size on the bottom of the box. The JB shall be suitable for surface mounting on ceiling/structures. The JB shall be of grey in color RAL 7035. All the metal parts shall be corrosion protected. Junction boxes surface should be such that it is free from crazing, blistering, wrinkling, color blots/striations. There should not be any mending or repair of surface. JBs will be provided with captive screws so that screws dont fall off when cover is opened. JBs mounting bracket should be of powder coated MS..

3.04.02

Terminal blocks shall be 650 volts grade, 10 Amps rated, made up of unbreakable polyamide 6.6 grade, complete with insulating barriers. Clip on type terminals, washer, nuts and identification strips. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be non ferrous. WAGO terminal of cage clamp with lugs shall also be acceptable. All terminal blocks shall be suitable for terminating on each side two (2) nos. stranded copper conductors of size up to 2.56 sq mm each. Terminations & Straight Through Joints Termination and jointing kits for 33kV, 11 kV and 3.3 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested. Termination kits and jointing kits shall be pre-moulded type, taped type or heat shrinkable type. 33kV and 11 kV grade joints and terminations shall be type tested as per IS: 13573. 3.3 kV grade joints and terminations shall be type tested as per VDE 0278. Critical components used in cable accessories shall be of tested and proven quality as per relevant product specification/ESI specification. Kit contents shall be supplied from the same source as were used for type testing. The kit shall be complete with the aluminium solderless crimping type cable lugs & ferrule as per DIN standard. Straight through joint and termination shall be capable of withstanding the fault level of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 11 kV system and 25 kA for 1 sec with a dynamic peak of 62.5 kA for 3.3 kV system. Straight through joints shall have provisions for shield connection and earthing wherever required and complete with all accessories and consumables suitable for storage without deterioration at a temperature of 50 deg. C with shelf life of more than five years. 1.1 kV grade straight through joints shall also be of proven design. 1.1 KV grade STJ shall be of proven design. Motor terminal boxes should of sufficient size to accommodate the selected cables. In case the cable sizes can not be accommodated, power Junction boxes shall be provided with cable interconnection between Junction boxes and motor terminal box. Cable glands Cable shall be terminated using double compression type cable glands. Cable glands shall conform to BS:6121 and be of robust construction capable of clamping cable and cable armour firmly without injury to insulation. Cable glands shall be made of heavy duty brass machine finished and nickel chrome plated. Thickness of
SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

3.05.00 3.05.01

3.05.02

3.05.03 3.05.04

3.06.00 3.06.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 5 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS plating shall not be less than 10 micron. All washers and hardware shall also be made of brass with nickel chrome plating Rubber components shall be of neoprene and of tested quality.

3.06.02 3.06.03

Cable lugs/ferrules Cable lugs for power cables shall be tinned copper solderless crimping type conforming to IS: 8309 suitable for aluminium compacted conductor cables. Cable lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . The cable lugs for control cables shall be provided with insulating sleeve and shall suit the type of terminals provided on the equipments. Trefoil clamps Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts, washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand the forces generated by the system short circuit current of 105 KA peak. Cable Clamps & Straps The cable clamps required to clamp multicore cables on vertical run shall be made up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, selflocking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps shall have sufficient strength and shall not get affected by direct exposure to sun rays and outdoor environment Receptacles Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm. The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes, mounting brackets suitable for surface mounting on wall/column/structure, gland plate etc. The ON-OFF switch shall be rotary type heavy duty double break, AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast Aluminium. Socket shall be provided with lid safety cover. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only when the switch is in OFF position. Also cover can be opened only when the switch is in OFF position. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. The Terminal blocks shall be of 750 V grade TPN 63A welding sockets with switch having degree of protection of IP-55 shall be provided in the following areas. 1) 2) 1 no. in each Switchgear/MCC rooms and Pump house. Maximum three (3) nos. of receptacles can be connected to one circuit. These receptacles shall be energised from MCC.

3.07.00 3.07.01

3.08.00 3.08.01

3.09.00 3.09.01

3.09.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

PAGE 6 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Galvanising Galvanising of steel components and accessories shall conform to IS:2629, IS:2633 & IS 4759. Additionally galvanising shall be uniform, clean smooth, continuous and free from acid spots The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers shall be as per IS:1367. The removal of extra zinc on threaded portion of components shall be carefully done to ensure that the threads shall have the required zinc coating on them as specified. However nuts and bolts of size lesser than M12 can be electro galvanised / electro plated. Welding The welding shall be carried out in accordance with IS: 9595. All welding procedures and welders qualification shall also be followed strictly in line with IS:9595 EXPANSION FASTNER Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion fastener shall only be used wherever insert plates are not available for supporting the cable structure. INSTALLATION Cable tray and Support System Installation Cables shall run in cable trays mounted horizontally or vertically on cable tray support system which in turn shall be supported from floor, ceiling, overhead structures, trestles, pipe racks, trenches or other building structures. All cable trays shall be in vertical configuration in boiler, CHP & ESP areas. Horizontally running cable trays shall be clamped by bolting to cantilever arms at an interval of 2000 mm. Vertically running cable trays shall be bolted to main support channel by suitable bracket/clamps on both top and bottom side rails at an interval of 2000 mm. For vertical cable risers/shafts cable trays shall be supported at an interval of 1000mm. Fixing of cable trays to cantilever arms or main support channel by welding shall not be accepted. Cable tray installation shall generally be carried out as per the enclosed drawings. The cantilever arms shall be positioned on the main support channel with a minimum vertical spacing of 300 mm unless otherwise indicated in the relevant tray layout drawings All cable way sections shall have identification, designations as per cable way layout drawings and painted/stenciled at each end of cable way and where there is a branch connection to another cable way. Minimum height of letter shall be not less than 75 mm. For long lengths of trays, the identification shall be painted at every 10 meter. Risers shall additionally be painted/ stenciled with identification numbers at every floor. In certain cases it may be necessary to site fabricate portions of trays, supports and other non standard bends where the normal prefabricated trays, supports and
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

3.10.00 3.10.01

3.10.02

3.11.00 3.11.01 3.12.00 3.12.01

4.00.00 4.01.00 4.01.01

4.01.02

4.01.03

4.01.04

4.01.05

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 7 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS accessories may not be suitable. In such cases the Contractor shall fabricate at site suitable sections of trays, supports and accessories to make the installation complete for the specific purpose after obtaining Project Manager's prior approval, which shall be neat in appearance and shall match with the prefabricated sections in the dimensions. They shall be applied with one coat of red lead primer, one coat of oil primer followed by two finishing coats of aluminium paint.

4.02.00

Conduits/Pipes/Ducts Installation The Contractor shall be fully responsible for properly embedding conduit pipe sleeves wherever necessary for cabling work. All openings in the floor/roof/wall / cable tunnel/cable trenches made for conduit installation shall be sealed and made water proof by the Contractor.

4.02.01

GI pull wire of adequate size shall be laid in all conduits before installation. Metallic conduit runs at termination shall have two lock nuts wherever required for junction boxes etc. Conduit runs/sleeves shall be provided with PVC bushings having round edge at each end. All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with Glass wool/Cement Mortar/Putty to prevent entrance of moisture and foreign material Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by other approved means. Conduits /pipe support shall be installed square and true to line and grade with an average spacing between the supports as given below, Conduit /pipe size (dia). Upto 40 mm 50 mm 65-85 mm 100 mm Spacing 1M 2.0 M 2.5 M 3.0 M

4.02.02

4.02.03

4.02.04 4.03.00 4.03.01

For bending of conduits, bending machine shall be arranged at site by the contractor to facilitate cold bending. The bends formed shall be smooth. Junction Boxes Installation Junction boxes shall be mounted at a height of 1200mm above floor level or as specified in the drawings or as decided by Project Manager and shall be adequately supported/mounted on masonry wall by means of anchor fasteners/ expandable bolts or shall be mounted on an angle, plate or other structural supports fixed to floor, wall, ceiling or equipment Cable Installation (for cables upto & including 33kV grade) Cable installation shall be carried out as per IS:1255 and other applicable standards. Cable drums shall be unloaded, handled and stored in an approved manner on hard
SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

4.03.02 4.03.03

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PAGE 8 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS and well drained surface so that they may not sink. In no case shall be drum be stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as possible. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on cable wheels and shall be rolled slowly so that cable comes out over the drum and not from below. All possible care shall be taken during unreeling and laying to avoid damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed plastic caps to prevent damage and ingress of moisture.

4.03.04

While laying cable, ground rollers shall be used at every 2 mtr interval to avoid cable touching ground. The cables shall be pushed over the rollers by a gang of people positioned in between the rollers. Cables shall not be pulled from the end without having intermediate pushing arrangements. Pulling tension shall not exceed the values recommended by cable manufacturer. Selection of cable drums for each run shall be so planned so as to avoid using straight through joints. Care should be taken while laying the cables so as to avoid damage to cables. If any particular cable is damaged, the same shall be repaired or changed to the satisfaction of Project Manager. Cables shall be laid on cable trays strictly in line with cable schedule furnished. Where specific cable layouts are not shown on drawings, Contractor shall route these as directed by the Project Manager Power and control cables shall be laid on separate tiers. The laying of different voltage grade cables shall be on different tiers according to the voltage grade of the cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables of subsequent lower voltage grades on lower tiers of trays. Single core cable in trefoil formation shall be laid with a distance of four times the diameter of cable between trefoil center lines and clamped at every 2mtr. All multicore cables shall be laid in touching formation. Power and control cables shall be secured fixed to trays/support with self locking type nylon cable straps with de-interlocking facilities. For horizontal trays arrangements, multicore power cables and control cables shall be secured at every five meter interval. For vertical tray arrangement, individual multicore power cables and control cables shall be secured at every one meter by nylon cable strap. After completion of cable laying work in the particular vertical tray, all the control cables shall be binded to trays/supports by aluminium strips at every five meter interval and at every bend. Bending radii for cables shall be as per manufacturers recommendations and IS:1255. Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC pipe. In each cable run some extra length shall be kept at suitable point to enable one LT/two HT straight through joints to made, should the cable develop fault at a later stage. Control cable termination inside equipment enclosure shall have sufficient lengths so that shifting of termination in terminal blocks can be done without requiring any splicing.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

4.03.05

4.03.06

4.03.07 4.03.08 4.03.09

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 9 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Wherever few cables are branching out from main trunk route troughs shall be used. The installation work shall be carried out in a neat workman like manner & areas of work shall be cleaned of all scraps, water, etc. after the completion of work in each area every day. Contractor shall replace RCC/Steel trench covers after the Installation work in that particular area is completed or when further work is not likely to be taken up for some time. Separation In vertically stacked trays, at least 300mm clearance shall be provided between : HT power & LT power cables, LT power & LT control cables

4.03.10 4.03.11

4.03.12

4.03.13

Segregation 1) 2) Segregation means physical isolation to prevent fire jumping.

All the cables of one stream shall be segregated from the cables of the other stream and shall run on either side of the trestle.

4.03.14

All field switches for equipments corresponding to a stream located within a radius of 4-5 mtr. shall be wired out to a field junction box and from field junction box to control panel/Input Output cabinet by screened instrumentation cables. Directly Buried Cables a) Cable trenches shall be constructed for directly buried cables. Construction of cable trench for cables shall include excavation, preparation of sieved sand bedding, riddled soil cover, supply and installation of brick or concrete protective covers, back filling and compacting, supply and installation of route markers and joint markers. Laying of cables and providing protective covering shall be as per IS:1255 and the enclosed drawings showing cabling details. RCC cable route and RCC joint markers shall be provided wherever required. The voltage grade of the higher voltage cables in route shall be engraved on the marker. Location of underground cable joints shall be indicated with cable marker with an additional inscription Cable Joint. The marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change in direction. They shall be located on both sides of road crossings and drain crossings. Top of cable marker/joint marker shall be sloped to avoid accumulation of water/dust on marker.

4.03.15

b)

4.03.16

Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable tags shall also be provided inside the switchgear, motor control centers, control and relay panels etc. where a number of cables enter together through a gland plate. Cable tag shall be of
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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CLAUSE NO.

TECHNICAL REQUIREMENTS rectangular shape for power cables and control cables. Cable tag shall be of 2 mm thick aluminum with number punched on it and securely attached to the cable by not less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively, the Contractor may also provide cable tags made of nylon, cable marking ties of TYCAB or equivalent type with cable number heat stamped on the cable tags

4.03.17 4.04.00 4.04.01

While crossing the floors, unarmoured cables shall be protected in conduits upto a height of 500 mm from floor level if not laid in tray. Cable Terminations & Connections The termination and connection of cables shall be done strictly in accordance with cable termination kit manufacturer instructions, drawings and/or as directed by Project Manager. Cable jointer shall be qualified to carryout satisfactory cable jointing/termination. Contractor shall furnish for review documentary evidence/experience reports of the jointers to be deployed at site. Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing, soldering, drilling, cutting, taping, preparation of cable end, crimping of lug, insulated sleeving over control cable lugs, heat shrinking (where applicable), connecting to cable terminal, shorting and grounding as required to complete the job to the satisfaction of the Project Manager. The equipment will be generally provided with undrilled gland plates for cables/conduit entry. The Contractor shall be responsible for punching of gland plates, painting and touching up. Holes shall not be made by gas cutting. The holes shall be true in shape. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium sheets. Control cable cores entering control panel/switchgear/MCC/miscellaneous panels shall be neatly bunched, clamped and tied with self locking type nylon cable ties with de interlocking facility to keep them in position. The panels where a larger number of cables are to be terminated and cable identification may be difficult, each core ferrule shall include the complete cable number as per the drawings. The ferrules shall be indelible interlocking type and shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter S alongwith cable numbers and coiled up after end sealing. All cable terminations shall be appropriately tightened to ensure secure and reliable connections. It is the responsibility of the Contractor to terminate the cables at motor terminals in correct phase sequence to ensure the proper direction of rotation. EARTHING SYSTEM Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity Rules/Acts.

4.04.02

4.04.03

4.04.04

4.04.05

4.04.06 4.04.07 5.00.00 5.01.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 11 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS All buildings / structures shall be interconnected together by min. two parallel conductors. Contractor shall furnish the detailed design calculations for the earthing system. Contractor shall obtain all necessary approvals for the system.

5.02.00 5.03.00

The earth conductors shall be free from pitting, laminations, rust, scale and other electrical, mechanical defects The material of the earthing conductors shall be as follows : 1) 2) 3) Conductors above ground level and in built up trenches. Conductors buried in earth Earth electrodes Galvanized steel Mild steel Mild steel rod

5.04.00

The sizes of earthing conductors for various electrical equipments shall be as below: Equipment Earth conductor buried in earth Earth conductor above ground level & in built-up trenches 65x8mm GS flat 65x8mm GS flat

a) b)

Main earth grid 33KV/11KV switchgear/equipment switchgear 415V

40 mm dia.MS rod ---

c)

3.3 kV switchgear / 415 V MCC/ Distribution boards / Transformers LT Motors above 125 KW 25 KW to 125 KW 1KW to 25 KW Fractional House power motor

---

50x6mm GS flat

d)

---------------

50 x 6mm GS flat 25 x 6mm GS flat 25 x 3mm GS flat 8 SWG GS wire 25 x 3 mm GS flat 8 SWG GI wire 50x6mm GS flat

e) f) g)

Control panel & control desk Push button station / Junction Box Columns, structures, cable trays and busduct enclosures

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PAGE 12 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

h)

Crane, rails, rail tracks & other non-current carrying metal parts

25x6mm GS flat

5.05.00

Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity, Crane rails, tracks, metal pipes and conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs, and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Employer. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Railway tracks within the plant area shall be bonded across fish plates and connected to earthing grid at several locations. Portable tools, appliances and welding equipment shall be earthed by flexible insulated cable. One separate core in the trailing/flexible cables shall be used for earthing purposes of the moving machines. PLC equipment shall be earthed separately as per the recommendations of the PLC manufacturer. Each continuous laid lengths of cable tray shall be earthed at minimum two places by G.S. flats to earthing system, the distance between earthing points shall not exceed 30mtr. Wherever earth mat is not available Contractor shall do the necessary connections by driving an earth electrode in the ground. Neutral points of HT transformer shall be earthed through NG resistors. The Contractor shall connect the NGR earthing point to earth electrodes by suitable earth conductors. Neutral connections and metallic conduits/pipes shall not be used for the equipment earthing. Lightning protection system down conductors shall not be connected to other earthing conductors above the ground level. Connections between earth leads and equipment shall normally be of bolted type. Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted connections after being tested and checked shall be painted with anti corrosive paint/compound. Suitable earth risers as approved by Project Manager shall be provided above finished floor/ground level, if the equipment is not available at the time of laying of main earth conductor. Connections between equipment earthing leads and between main earthing conductors shall be of welded type. For rust protection the welds should be treated with red lead compound and afterwards thickly coated with bitumen compound. All welded connections shall be made by electric arc welding. Resistance of the joint shall not be more than the resistance of the equivalent length of conductors.

5.06.00

5.07.00

5.08.00

5.09.00

5.10.00

5.11.00

5.12.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 13 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Earthing conductors buried in ground shall be laid minimum 600 mm below grade level unless otherwise indicated in the drawing. Back filling material to be placed over buried conductors shall be free from stones and harmful mixtures. Back filling shall be placed in layers of 150 mm. Earthing conductors embedded in the concrete floor of the building shall have approximately 50 mm concrete cover. A minimum earth coverage of 300 mm shall be provided between earth conductor and the bottom of trench/foundation/underground pipes at crossings. Earthing conductors crossings the road can be installed in pipes. Wherever earthing conductor crosses or runs at less than 300 mm distance along metallic structures such as gas, water, steam pipe lines, steel reinforcement in concrete, it shall be bonded to the same. Earthing conductors along their run on columns, walls, etc. shall be supported by suitable welding / cleating at interval of 1000mm and 750mm respectively. Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded below permanent moisture level. Minimum spacing between electrodes shall be 600mm. Earth pits shall be treated with salt and charcoal if average resistance of soil is more than 20 ohm metre. On completion of installation continuity of earth conductors and efficiency of all bonds and joints shall be checked. Earth resistance at earth terminations shall be measured in presence of Employers representatives. All equipment required for testing shall be furnished by contractor. Earthing conductor shall be buried at least 2000mm outside the fence of electrical installations. Every alternate post of the fences and all gates shall be connected to earthing grid by one lead. LIGHTNING PROTECTION SYSTEM Lightning protection system shall be in strict accordance with IS:2309 Lightning conductor shall be of 25x6mm GS strip when used above ground level and shall be connected through test link with earth electrode/earthing system Lightning system shall comprise of air terminations, down conductors, test links, earth electrode etc. as per approved drawings Down Conductors 1. 2. Down conductors shall be as short and straight as practicable and shall follow a direct path to earth electrode. Each down conductor shall be provided with a test link at 1000 mm above ground level for testing but it shall be in accessible to interference. No connections other than the one direct to an earth electrode shall be made below a test point.

5.13.00

5.14.00 5.15.00

5.16.00 5.17.00

5.18.00

5.19.00

6.00.00 6.01.01 6.01.02 6.01.03 6.02.00

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PAGE 14 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS

3. 4. 5.

All joints in the down conductors shall be welded type. Down conductors shall be cleated on outer side of building wall, at 750 mm interval or welded to outside building columns at 1000 mm interval. Lightning conductor on roof shall not be directly cleated on surface of roof. Supporting blocks of PCC/insulating compound shall be used for conductor fixing at an interval of 1500 mm. All metallic structures within a vicinity of two meters of the conductors shall be bonded to conductors of lightning protection system. Lightning conductors shall not pass through or run inside GI Conduits. Testing link shall be made of galvanized steel of size 25x 6mm.

6. 7. 8. 7.00.00 7.01.00

QUALITY ASSURANCE PROGRAMME Bidder shall furnish detailed Quality Assurance Program and Quality Plans for all materials and accessories to be supplied and installed under the scope of the specification as per General Technical Conditions of technical specification. The Quality Plans shall include all tests/ checks as per relevant National/International Standards and the requirements of this specification including tests listed in this section. TESTS All equipment to be supplied shall be of type tested design. The contractor shall submit for Owner's approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. In case the contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in the case of type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

8.00.00 8.01.01

8.01.02

8.01.03

8.01.04

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 15 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS Type Test reports shall be furnished for the following Cable termination kit and straight through joints should have been tested as per IS: 13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class. Routine/ Acceptance Tests Routine Tests a) b) c) d) Routine tests as per specification and applicable standards shall be carried out on all equipments/items covered in the specification. Physical & dimensional check on all equipments as per approved drawings/standards. HV/IR as applicable. Check/measurement of thickness of paint/zinc coating/nickel-chrome plating as per specification & applicable standard.

8.02.00 8.02.01 8.03.00 8.03.01

8.03.02

Acceptance Test a) b) c) Galvanising Tests as per applicable standards Welding checks Deflection tests on cable trays: One piece each of 2.5m length of cable tray of 300mm & above shall be taken as sample from each offered lot. It shall be supported at both end & loaded with uniform load of 76 kg/meter along the length of cable tray. The maximum deflection at the mid-span of each size shall not exceed 7mm. d) Proof load tests on cable tray support system i) Tests on Main Support Channel shall be done if only C1 Channel are in scope of supply and cantilever arms shall be fitted on one side. This test shall be same as test 4 of type test. Test on Main Support Channel shall be done with C2 channel and cantilever arms fitted on both sides, if C2 channels are in scope of supply. This test shall be same as test 2A of type test. Then test (i) above shall not be done. Nut slip characteristic test (it shall support minimum load of 350kg before nut slips with a bolt torque of 65 NM). This test shall be same as test 5B3 of type test. The procedure for carrying out tests at d above shall be as per details given in Type Tests in specification thereafter Die-Penetration test shall be carried out to check weld integrity. e) The above acceptance tests shall be done only on one sample from each offered lot.

ii)

iii)

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PAGE 16 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS COMMISSIONING The Contractor shall carry out the following commissioning tests and checks after installation at site. In addition the Contractor shall carry out all other checks and tests as recommended by the Manufacturers. Cables a) b) c) d) e) Check for physical damage Check for insulation resistance before and after termination/jointing. HT cables shall be pressure tested (test voltage as per IS:7098) before commissioning. Check of continuity of all cores of the cables. Check for correctness of all connections as per relevant wiring diagrams. Any minor modification to the panel wiring like removing/inserting, shorting, change in terminal connections etc., shall be carried out by the Contractor at no extra cost. Check for correct polarity and phasing of cable connections. Check for proper earth connections for cable glands, cable boxes, cable armour, screens, etc. Check for provision of correct cable tags, core ferrules, and tightness of connections.

9.00.00 9.01.01

9.01.02

f) g) h)

9.02.00

Cable trays / supports and accessories 1) 2) 3) 4) Check for proper galvanizing/painting and identification number of the cable trays/supports and accessories. Check for continuity of cable trays over the entire route. Check that all sharp corners, burrs, and waste materials have been removed from the trays supports. Check for earth continuity and earth connection of cable trays.

9.03.00

Earthing and Lightning protection system 1) 2) Earth continuity checks. Earth resistance of the complete system as well as sub-system.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-08 CABLING, EARTHING & LIGHTNING PROTECTION

PAGE 17 OF 18

CLAUSE NO.

TECHNICAL REQUIREMENTS GENERAL COMMISSIONING CHECKS (Application to all electrical equipments) (a.) (b.) (c.) (d.) (e.) (f.) (g.) Check for name plate details according to specification. Check for physical damage, if any. Check for tightness of all bolts, clamps & connecting terminals. Check for earth connection. Check for cleanliness of insulators & bushings. Check for lubrication of all moving parts. Check for provision of heater.

9.04.00

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PAGE 18 OF 18

PART - B SUB-SECTION-IIIB-09 TRANSFORMERS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

TRANSFORMER 1.00.00 1.01.00 CODES AND STANDARDS Transformers Bushing CTs Insulating oil 2.00.00 2.01.00 TYPE Out-door Transformers Dry type Transformers FEATURES Paint shade Degree of protection : Dry type transformer Cable box, Marshalling box 4.00.00 4.01.00 TEMPERATURE RISE Out-door Transformers Dry type Transformers Winding 55oC above ambient 50oC oil 50oc above ambient 50oC. Winding (by resistance method) : 90oC or lower as permissible for class of insulation offered, above ambient of 50oC RAL 5012 Mineral oil filled ONAN type, Three phase unit IEC:60076, IEC 60354, IEC:60726 IEC :60044-1 IEC: 60296

2.02.00

Epoxy cast resin/resin encapsulated air cooled type, Three phase unit

3.00.00

IP-23 IP-55

4.02.00

5.00.00 5.01.00

OPERATIONAL REQUIRTEMENTS Tap Changer Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by an external handle with position markings, pad locking facility in each position and mechanical stops to prevent over cranking beyond extreme positions in case of outdoor type transformers. In case of indoor transformers, it shall be with shrouded bolted links.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-09 TRANSFORMERS

PAGE 1 OF 6

CLAUSE NO.

TECHNICAL REQUIREMENTS

5.02.00

Loading Capability Continuous operation at rated KVA on any tap with voltage variation of +/-10% corresponding to the voltage of the tap as well as in accordance with IEC 354.

5.03.00

Flux Density Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from voltage corresponding to the tap. Transformer shall also withstand following overfluxing conditions due combined voltage and frequency fluctuations: a) b) c) 110% for continuous rating. 125% for at least one minute. 140% for at least five seconds. :Not to exceed values specified in NEMA TR-1.

5.04.00 6.00.00

Noise Level

DESIGN AND CONSTRUCTIONAL FEATURES All transformers shall be suitable for cable or bus duct termination as contemplated. If cable connection is envisaged, a dust tight cable box shall be provided. Also, a sheet steel, vermin and dust proof marshalling box shall be furnished with each transformer to accommodate temperature indicators, terminal blocks for control cables etc. The transformer shall be provided with all fittings and accessories to be complete in all respects for satisfactory operation.

6.01.00 6.01.01

OUTDOOR TRANSFORMERS a) Tank Shall be fabricated from tested quality steel and designed to withstand continuous internal pressure of 35KN per sq.m. over normal pressure as well as short circuit forces. The main tank body shall be capable of with standing vacuum as per CBIP guidelines. All steel surfaces in contact with insulating oil shall be painted with two coats of heat resistant oil in soluble insulating paint. Tank shields, if provided, shall not resonate at natural frequency of equipment. b) Tank mounting Transformer tank shall be mounted on bi-directional rollers. Suitable locking arrangement shall be provided to prevent accidental movement of

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 2 OF 6

CLAUSE NO.

TECHNICAL REQUIREMENTS

transformer. Tank shall also be provided with lifting lugs and minimum four jacking pads. c) At least two adequately sized inspection openings, one at each end of the tank for easy access to bushings and earth connections shall be provided.

6.01.02

Core shall be High grade non-ageing cold rolled grain oriented silicon steel laminations. Winding conductor shall be Electrolytic grade copper. Windings of 66kV and below shall be uniformly Insulated. Conservator tank of adequate capacity for expansion of oil from min. ambient to 100 deg.C. shall be provided. The transformers rated 7.5 MVA and above shall be provided with air bag breathing through silica gel breather. For lower rating transformers, conventional single compartment conservator with dry air filling the space above oil and connected to silica gel breather shall be provided. Bushings shall be Porcelain. Bushing CTs Shall be provided in the LV neutral side of adequate rating for REF protection, Back up definite time earth fault protection (for HT transformers only), WTI, etc. Radiators shall be Tank mounted with shut off valves. Insulating oil No external inhibitors are permitted.

6.01.03

6.01.04

6.01.05 6.01.06

6.01.07 6.01.08

6.01.09 6.01.10

Marshalling box shall be provided with thermostatically controlled space heaters. The insulation of core to core clamp shall be able to withstand a voltage of 2 KV rms for one (1) minute. Fittings Transformer shall be provided with following fittings as minimum a) Buchholz relay shall be provided with double float type with alarm and trip contacts, alongwith suitable gas collecting device. At least two numbers of spring operated pressure relief devices with extension pipe to bring oil to plinth level along with electrically insulated

6.01.11

b)

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PAGE 3 OF 6

CLAUSE NO.

TECHNICAL REQUIREMENTS

contact for alarm and tripping shall be provided for transformer rating 2MVA and above. c) Diaphragm type explosion vent shall be provided for all transformers below 2 MVA rating. Winding temperature indicator (WTI) and Oil temperature indicator (OTI), Dial type (150mm) with alarm and trip contacts and max. reading pointer along with resetting device shall be provided. Magnetic oil level gauge with alarm contact shall be provided. Oil level gauge Prismatic/toughened glass type.

d)

e) f) 6.02.00 6.02.01

DRY TYPE TRANSFORMERS Enclosure Enclosure shall be of a tested quality sheet steel of minimum thickness 2mm & shall also accommodate cable terminations. The housing door shall be interlocked such that it should be possible to open the door only when transformer is off. The enclosure shall be provided with lifting lugs and other hardware for floor mounting.

6.02.02

Core Shall be High grade non-ageing cold rolled grain oriented silicon steel laminations. CRGO silicon steel.

6.02.03

Winding conductor

Shall be electrolytic grade copper or aluminium. Windings shall be of class F insulation. Shall be Solid porcelain / RIP. Shall be provided in the LV neutral side with adequate rating for REF protection, WTI, etc.

6.02.04 6.02.05 6.02.06

Bushings Bushing CTs Fittings Winding temperature Indicator (WTI) Thermistors

Shall be Platinum resistance type temperature detector in each limb. Shall be embedded in each limb with alarm and trip contacts for remote annunciation.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 4 OF 6

CLAUSE NO.

TECHNICAL REQUIREMENTS

7.00.00 7.01.00

TRANSFORMER SIZING Size of the transformer shall be decided based on following : Size shall be greater than or equal to total KVA of continuous load + (coincident factor x total kVA of intermittent load other than valves) + 0.2 x total valves kVA + kVA of largest rated valve or damper motor + Employer's requirement, if any. + 10% margin on the sum of the above mentioned values. Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be taken as 0.5. Both streams from Track hopper upto and including TP-1 loads shall be considered running simultaneously for sizing the respective transformers.

7.02.00

Normally 2 x 100% feeding arrangement shall be provided as shown in single line diagram i.e. the total loads to be considered for sizing each transformer shall be the loads working on both the buses. In case of 3 x 50% feeding arrangement, if required, the loads to be considered on each transformer shall be the loads working on any two of the buses. TYPE TESTS For each type and rating of transformers rated upto and including 2 MVA The Contractor shall submit for Employers approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the

8.00.00 8.01.00 8.01.01

8.02.00

8.03.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 5 OF 6

CLAUSE NO.

TECHNICAL REQUIREMENTS

manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet. 8.04.00 Following is the list of type tests (for dry type & Outdoor transformers) (a) (b) (c) Short circuit test Temp. rise test Lightning impulse(Chopped Wave) voltage test on all three limbs and full wave LI on neutral if grounded through NGR. Partial discharge test on dry type transformers only. Tank Pressure test on oil filled transformers Tank vacuum Test on oil filled transformers Noise level test as per NEMA TR-1 Degree of protection test for marshalling box. Zero sequence Impedance measurement Measurement of harmonics in no load current.

(d) (e) (f) (g) (h) (i) (j) 8.05.00

The following special tests on all transformers shall be conducted under this contract as routine tests in addition to all routine tests as per IEC 60076: (a) (b) (c) Oil leakage test for 24 hours Repeat no load loss tests after electrical tests. Measurement of capacitance & tan delta to determine capacitance between winding and earth.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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PAGE 6 OF 6

PART - B SUB-SECTION-IIIB-10 HT SWITCHGEAR

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

HT SWITCHGEAR 1.00.00 CODE AND STANDARDS IEC: 62271, IS:13118 and IS:3427 2.00.00 2.01.00 TYPE Switchgear Free standing, Floor mounted, metal clad, fully compartmentalized draw-out type 2.02.00 Circuit Breaker SF6 or Vacuum type, restrike free, trip free, stored energy operated and with electrical anti-pumping features 3.00.00 TEMPERATURE RISE Temperature rise of busbars shall not exceed 55 deg. C for silver plated joints and 40 deg. C for other joints, over an ambient temperature of 50 deg. C under any condition. 4.00.00 4.01.00 OPERATIONAL REQUIREMENT Each breaker panel shall be provided with the following devices for control, indication and inter locking a) b) Spring return to neutral type control switch (with NAC/NAT position) Stay put type selector switches. Voltmeter with selector switch shall be provided with each bus-section. On, Off, 'Auto trip' Spring charged and Control Supply healthy indicating lamps. The lamps shall be high intensity cluster type LED Service & test position indication shall be provided on all panels through additional lamps. Thermostatically controlled space heater with switch, illumination and power plug point. All meters/instruments shall be flush mounted on front panel, atleast 96 sq.mm size with 90 deg. scales and accuracy class of 2.0. All feeders shall have an ammeter and ammeter selector switch, voltmeter with voltmeter selector switch for each bus.

c)

d)

e)

4.02.00

The circuit breaker shall meet the following requirements a) The breaker shall be controlled locally and/ or remotely as required . Facilities shall be provided for mechanical tripping of breaker and manual charging of closing spring to cater to emergency condition.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 1 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS b) c) d) Surge arrestor shall be provided for each motor feeder. Shall have an Operation duty O-3 min -CO- 3min-CO. Closing and tripping coils operating under extreme conditions of control voltage variation. Supervision relays provided for trip coil monitoring. Suitable mechanical inter lock shall be provided to prevent inadvertent ear thing of any live part. Castle key interlocks shall be provided to prevent opening of cable compartment door when breaker is closed and bus bar compartment when any of the incomers to bus are closed. Testing of circuit breaker shall be possible in isolated position by keeping the control plug connected. Only motor wound closing spring charging arrangement is acceptable. In a switchgear if there are more than one possible feed (including bus coupler) then lockout relay (86) contact of incoming breakers shall be connected in series in closing circuit of each of incoming breakers. Automatic change-over shall be provided for bus sections with suitable synchronizing check facility. The change-over shall be blocked in case of fault on the bus section. Dead Bus change-over after voltage collapse shall also be provided as back-up. Core balance CTs shall be provided for outgoing motor and transformer feeders having CT ratios greater than 50/1A. Each breaker truck shall have Service - Isolated - Withdrawn Position. Primary fuse replacement shall be possible with VT in isolated position. Each feeder shall have local/remote selection feature. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position. Tripping from local shall be possible only when local / remote selector switch is in local position. Tripping from remote shall be possible either with breaker in service position or selector switch being in remote position.

e) f)

g)

h)

i) j)

k)

l)

m) n) o)

5.00.00

CONTACTORS (a.) The Bidder shall offer only HRC fuse backed, mechanically latched type contactor for outgoing motor feeder panels.

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 2 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS (b.) The medium voltage contactors shall be of AC-3 utilization category and shall be vacuum type. The fuse and contactor assembly shall be mounted on a withdrawable truck. Circuits shall be provided with suitable single phasing protection. If required the contactor coil shall have a suitable economy resistor in series and shall be rated for satisfactory operation at 80 to 110% of rated voltage. The fuse and overload protection shall be fully coordinated, so that the contactor operates only for a fault current less than its interrupting capability. The fuses shall be provided with mechanical trip indication. The contactors shall close satisfactorily with a control voltage between 85 to 110 per cent and trip satisfactorily with a control voltage between 70 to 100 percent of the rated control supply voltage. Mechanical indication of contactor open / closed shall be provided. An anti-pumping relay shall be provided even if it has mechanical anti-pumping feature. Trip circuit supervision relay shall be provided to monitor the healthiness of trip coil. Surge suppressors shall be provided on all contactor controlled motor feeders.

(c.)

(d.)

(e.)

6.00.00

SURGE ARRESTOR The surge arrestors shall be provided for all motor feeders and shall be metal oxide, gapless type generally in accordance with IEC 60099-4 and suitable for indoor duty. These shall be mounted within the switchgear cubicle between line and earth, preferably in the cable compartment. Surge arrestor selected shall be suitable for non-effectively earthed system and rating shall be in such a way that the value of steep fronted switching over voltage generated at the switchgear terminals shall be limited to the requirements of switchgear.

7.00.00 7.01.00

PROTECTION, CONTROL AND METERING The switchgears shall have Communicable Numerical relays for Protection, scheme, Metering and Status monitoring. Employer shall network the Numerical relays through Data Concentrators of the main plant to HMI and further integrated to DCS/DDCMIS system for diagnostics and status monitoring. All the feeders shall be remote controlled from DCS/PLC and from the local console of the numerical relays. GENERAL REQUIREMENTS OF NUMERICAL RELAYS All numerical relays, auxiliary relays and devices shall be of types, proven for the application; satisfying requirements specified elsewhere and shall be subject to Owner's approval. Numerical Relays shall have appropriate setting ranges, accuracy, resetting ratio, transient overreach and other characteristics to provide required sensitivity to the satisfaction of the Owner. All the numerical relays shall have communications on two ports, local front port communication to laptop and a second port on IEC 61850 port to communicate with the data concentrator through LAN and Ethernet switches.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-10 HT SWITCHGEAR

8.00.00 8.01.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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CLAUSE NO.

TECHNICAL REQUIREMENTS All relays and timers shall be rated for control supply voltage as mentioned elsewhere under parameters and shall be capable of satisfactory continuous operation between 80-120% of the rated voltage. Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to ensure avoidance of mal operation due to stray voltages. The protective relays shall have at least 8 Nos potential free contacts (Programmable) Auxiliary relays shall have contacts as required. Relay output contacts shall be suitable for directly wiring in the breaker closing and trip circuit operating from 220 V DC control voltage. Failure of a control or auxiliary supply and deenergisation of a relay shall not initiate any circuit breaker /contactor operation. All relays shall withstand a minimum test voltage of 2 KV AC Rms for one minute. All the numerical relays shall have communications on two ports; local front port communication to laptop and a second port on IEC 61850 port to communicate with the Employers data concentrator through LAN. Relays shall be suitable for electrical measurement including voltage, current, power (active/reactive) and energy parameters. Mapping details of all the details shall be submitted in IEC format. Relays shall have separate output for individual functionality and the master trip shall be software configurable in case of multi output relays. Relays shall have event recording feature, recording of abnormalities and operating parameters with time stamping Preferably comprehensive single numerical relay shall have provision of both current and voltage inputs. The current operated relay shall have provision for 4 sets of CT inputs, 3 nos. for phase fault & 1 CT input for earth fault. Relay shall be suitable for both residually connected CT input as well as CBCT input. The voltage-operated relay shall have provision for 3 PT inputs. Relays shall be suitable for CT secondary current of 1A/5A selectable at site. Relays used in incomers and bus couplers shall have provision of two sets of voltage signal inputs for the purpose of synchronization. All CT & PT terminals shall be provided as fixed type terminals on the relay to avoid any hazard due to loose connection leading to CT opening or any other loose connection. In no circumstances Plug In type connectors shall be used for CT / PT connections. Vendor to ensure the same for all protective relay models offered. All numerical relay shall have key pad / keys to allow relay settings from relay front. All hand reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. Manual resetting shall be possible from remote.

8.02.00

8.03.00

8.04.00

8.05.00

8.06.00

8.07.00 8.08.00

8.09.00

8.10.00

8.11.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 4 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS Relays shall have suitable output contact for breaker failure protection. Relays shall have self diagnostic feature with self check for power failure, programmable routines, memory and main CPU failures. Relays shall have at least two sets or groups of two different sets of adaptable settings. Relays shall have multiple IEC/ ANSI programmable characteristics. Design of the relay must be immune to any kind of electromagnetic interference. Vendor to submit all related type test reports for the offered model along with the offer. PROTECTIONS: RELAY TYPES/ PROTECTIONS A. Motor Feeders a) b) c) d) e) f) g) h) i) j) B. Thermal Overload Protection (50I) Restart Inhibit Protection (49) Earth Fault Protection (50N/50N2) Negative Phase Sequence Protection (46) Reversal Phase Sequence Protection (46 R) Locked Rotor Protection (50 L/R) Number of starts limitation (66) Loss of Load Protection (37) Under Voltage protection with timer(27 M) Energy Metering

8.12.00 8.13.00

8.14.00

8.15.00

9.00.00

Transformer Feeder Protections a) Three Phase Over current and Earth Fault protection (50 & 50 N1/50 N2))(The earth fault element should be suitable for both residually connected CT input as well as CBCT input.) Restricted Earth Fault protection (64 R) Transformer Differential protection (87 T) for Transformers with rating more than 5 MW Stand by earth fault protection (51 N) Transformer buchholz and WTI/OTI high trips Energy Metering

b) c) d) e) f)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 5 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS C. Protections for Incomers, Bus couplers and Tie feeders. a) b) c) Over current and earth fault protection. Synchronizing check relay as a part of fast change over scheme. Energy Metering

10.00.00 10.01.00

OTHER PROTECTIONS AND CONTROL FUNCTIONS IN THE RELAYS. For Breaker control from DCS/PLC, hardwired potential free contacts shall be provided from DCS/PLC, to the numerical relays. No separate coupling relays shall be provided. Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker/ contactor trip circuit both in pre trip and post trip conditions. Schematics requiring auxiliary relays /timers for protection function shall be a part of numerical relay. The number of auxiliary relay and timer function for protection function shall be as required. Auxiliary relays for interlocking purpose shall be of self reset type. Bus no volt condition shall be configured to a output contact of the relay of all incomers Timer functions shall be programmable for on/off delays. The numerical relay shall be able to provide supervisory functions such as trip circuit monitoring, circuit breaker state monitoring, PT and CT supervisions and recording facilities with Post fault analysis. The numerical processor shall be capable of measuring and storing values of a wide range of quantities, all events, faults and disturbance recordings with a time stamping using the internal real time clock. Battery back up for real time clock in the event of power supply failure shall be provided. 150 time tagged events /records should be able to store with time stamping Last 5 faults storage including the indication, protection operated , fault location relay and operating time, currents, voltage and time. Diagnostics Automatic testing, power on diagnostics with continuous monitoring to ensure high degree of reliability shall be shall be provided. The results of the self reset functions shall be stored in battery back memory. Test features such as examination of input quantities, status of digital inputs and relay outputs shall be shall be available on the user interface The alarm/status of each individual protection function and trip operation shall be communicated to DCS/PLC The numerical relay system shall have built-in features/hardware interface to provide such inputs to DCS/PLC for analog/digital values The provision of receiving the D.C. incoming supplies and its monitoring shall preferably be made in one bus P.T. Panel.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-10 HT SWITCHGEAR PAGE 6 OF 11

10.02.00

10.03.00

10.04.00

10.05.00 10.06.00

10.07.00

10.08.00

10.09.00

10.10.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS Sequence of events shall have 1 ms resolution at device level. Measurement accuracy shall be 1 % for RMS Current and voltage. It shall be possible to carryout open / close operation of breakers from a laptop by interfacing from the relay front port (RS232) during initial commissioning. ETHERNET SWITCHES Ethernet switches shall be substation hardened and shall comply to IEC61850-3 for communications and environment requirements. The Ethernet switches shall be of managed type with two(2) No of Fibre optic cable ports and Fourteen/Six of Copper ports to achieve the LAN configuration. These switches shall be mounted inside the switchgear Panel.

10.11.00 10.12.00 10.13.00

11.00.00

12.00.00

AUXILIARY POWER SUPPLY Relay shall be suitable to accept both AC & DC supplies with 110V AC or 220V DC with tolerance of 80% to 120 % of rated voltage.

12.01.00

Input / Output Interface, Filters And Optical Isolation Relay shall be immune to capacitance effect due to long length of connected control cables. Any external hardware, if required for avoiding mal operation of the relay due to cable capacitance shall be included as a standard feature. All I/Os shall have optical isolation. Analog inputs shall be protected against switching surges, harmonics etc. No separate earth bus shall be required for the relays. It shall be possible to connect the relay earth to the common earth bus in the switchgear panel which shall be connected to the plant earth mat.

13.00.00

SOFTWARE SECURITY, LICENSE AND UP GRADATIONS Numerical relays shall have two level pass word protections, one for read only and other for authorization for modifying the setting etc.

14.00.00

DESIGN AND CONSTRUCTION FEATURES All HT switchgear panels and circuit breakers shall have the following features. a) High conductivity aluminum alloy or copper for the horizontal bus bars, vertical droppers and connectors to the fixed end of isolating contacts. Height of the Switchgear Panel not to exceed 2600 mm. Insulators shall be track-resistant, high strength, non-hygroscopic, non-combustible type and suitable withstand stresses due to over-voltages and short circuit current. Inter pole barrier of inflammable material like hylam not acceptable

b) c)

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 7 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS d) Sealing: Bushing or other sealing arrangement shall be provided between breaker and bus bar / cable compartments to avoid air communication around isolating contacts in the safety shutter area with truck in service position. e) Construction (i) (ii) The switchgear assembly shall be rodent and vermin proof. In switchgear design where the breaker front itself serves as a door suitable blanking covers one for each size of panel per switch board shall be included. The switchgear enclosure shall be constructed with rolled steel section of rolled sheet steel of at least 2.0 mm thickness. Pressure relief device shall be provided in each high voltage compartment to vent out safely the gases produced in case of a fault. Breaker trucks shall have a secure locking in SERVICE position so that they are not displaced during a short circuit. Current ratings of all switchgears, circuit breakers, CT's etc. shall be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life. Use of two breakers in parallel to meet the required rating shall not be acceptable. HT switchgear shall also have at least two (2) fully equipped spare feeders on each bus section.. Suitable trolley arrangement, if required, shall be provided. One trolley per switchgear room shall be provided suitable for each type of rating of breakers. Switchgear panels shall be suitable for bottom cable entry and shall be provided with removable gland plates.

(iii)

(iv)

(v)

(vi)

(vii)

(viii)

(ix)

f)

Earthing Arrangement (i) Internal earth bus shall be provided which has a capacity to withstand short circuit currents for one second and all enclosures shall be connected to this bus. Earthing arrangement through and integral earth switch or through separate Earthing truck shall be provided. Suitable mechanical interlocks shall be provided to prevent the closing of earth switch circuit on live circuit. In case of later arrangement one set of different types of Earthing trucks per switch board shall be provided.

(ii)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 8 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS (iii) Earthing switch/Earthing truck shall be short time (One second) current withstand capability equal to the breaker. A clearly visible warning label "ISOLATE ELSEWHERE BEFORE EARTHING" shall be provided on shutters of incoming and other connections which could be energized from other end.

(iv)

g)

Switchgear panel shall be suitable for bottom entry and provided with removable gland plates. Instrument transformer CTs and VTs shall be provided for protection and metering and shall be cast-resin encapsulated type. Insulation class 'E' or better. VTs shall have suitable HRC current limiting fuses to both primary and secondary sides, under voltage relays, timers, etc. for motor tripping and remote annunciation on supply failure. Each switchgear section shall have a three phase VT. Single phase VT shall be provided for HT incomers for synchronization. Accuracy class of CTs and VTs shall be as follows CT Protection/ Metering Differential/REF PS 5P 10 1.0 Core balance CTS PS

h)

j)

SF6 monitoring SF6 gas pressure / density monitoring for low pressure alarm/ interlock shall be provided.

k)

Identification plates Each panel to be identified on front as well as back side by large engraved plate giving detailed feeder description. Identification labels/painted (Not stickers) plates to be provided inside each panel.

l)

Safety Requirements The switchgears shall be designed to offer adequate level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate shall be provided for each switch gear room mounting on wall describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear. Rubber mats shall be provided in front of each panel.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 9 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS Safety shutters complying with IEC-60298 shall be provided to cover up the fixed high voltage contacts on busbar and cable sides when the truck is moved to ISOLATED position The breaker / contactor and the auxiliary compartments provided on the front side shall have strong hinged doors. Busbar and cabling compartments provided on the rear side shall have separate bolted covers with self retaining bolts for easy maintenance and safety. Breaker / Contactor compartment doors shall have locking facility. Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the back doors.

15.00.00

DEGREE OF PROTECTION OF VARIOUS ENCLOSURES: i) ii) VT Relay compartmrnt Other compartments IP-52 IP-41

16.00.00

PAINT SHADE : Complete panels excluding end covers Extreme end covers of all boards RAL 9002 RAL 5012

17.00.00

TYPE TESTS (a) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

(b.)

(c.)

(d)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 10 OF 11

CLAUSE NO.

TECHNICAL REQUIREMENTS The contractor shall submit the following type test reports. a) The following type tests Reports shall be furnished for circuit breaker / circuit breaker panels, of each voltage class and current rating. 1) 2) 3) 4) 5) 6) Short circuit duty test on circuit breaker Short time withstand test on circuit breaker Power frequency withstand test Lightning impulse withstand test Temperature rise test on breaker and panel together. Test to verify pressure relief devices operation of the panel. This shall be done on one panel of each voltage class. Measurement of resistance of main circuit. Mechanical operation test.

7) 8) b)

Contactor and Contactor panels of each type and rating. 1) Verification of rated making and breaking capacities of the contactor. Short time withstand test of panel. Power frequency test on the contactor Lightning impulse voltage withstand test Measurement of resistance of main circuit. Test to confirm coordination between fuse and contactor.

2) 3) 4) 5) 6) c) d) e)

Type Tests Reports for Surge arrestors as per IEC/IS. Short circuit withstand test of earthing device (truck / switch). Type test Reports as per IEC 61850 for numerical relays.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-10 HT SWITCHGEAR

PAGE 11 OF 11

PART - B SUB-SECTION-IIIB-11 BATTERY

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

BATTERY 1.00.00 BATTERY RATINGS DC systems of 220V voltage level shall be provided for coal handling plant. The system shall comprise of two batteries and two float-cum-boost chargers. CHP battery shall be sized for a period of at least 30 minutes for the CHP DC loads. The battery shall also be sized considering a minimum electrolyte temperature of 15 deg C and an ageing factor of 1.2. The minmum capacity shall be 100AH for Nickel cadmium & 170AH for Lead Acid plante battery. Battery sizing shall take into account the emergency lighting in CHP equipment buildings as detailed elsewhere in technical specifications, in addition to continuous DC loads of various MCCs/Swgr and control panels. PART-A: NICKEL-CADMIUM BATTERY 2.00.00 2.01.00 CODES AND STANDARDS All standards, specifications and codes of practice referred to herein, shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes: IS : 10918 IS : 1069 Specification for vented type Nickel Cadmium Batteries. Quality tolerances for water for storage batteries Indian electricity rules Indian Electricity Acts. 2.02.00 Equipment complying with other internationally accepted standards such as IEC., BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards along with copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. GENERAL TECHNICAL REQUIREMENT Equipments (a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type conforming to IS:10918. For the purpose of design an ambient temperature of 50 degree centigrade and relative humidity of 85% shall be considered.

3.00.00 3.01.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-11 BATTERY

PAGE 1 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS (b.) DC batteries shall be suitable for standby duty. The batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell. The number of cells for the 220 Volts shall be 169. Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.

(c.) (d.) 3.02.00 3.02.01

Construction Features Containers Containers shall be made of polypropylene plastic material. Containers shall be robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of translucent containers.

3.02.02

Vent Plugs Vent plugs shall be provided in each cells. They shall be anti splash type, having more than one exit hole shall allow the gases to escape freely but shall prevent alkali from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte samples.

3.02.03

Plates The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS:10918. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative terminal posts shall be clearly marked.

3.02.04

Sediment Space Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.

3.02.05

Cell Insulator Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on to the racks with adequate clearance between adjacent cells. Minimum

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-11 BATTERY

PAGE 2 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS distance between the adjacent cells shall be more than the budge allowed for two cells in accordance with IS: 1146.

3.02.06

Electrolyte The electrolyte shall be prepared from battery grade potassium hydroxide conforming to BS: 1069. The cells can be shipped either in charged condition or in dry condition Necessary electrolyte for make-up shall be supplied separately.

3.02.07

Connectors and Fasteners Nickel coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent corrosion. The thickness of Nickel coating of connectors should be not less than 0.02 mm. All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same. Suitable number of Inter-rack connectors shall be supplied by the Bidder to suit the battery room layout during detailed engineering.

3.02.08

Battery racks Mild steel racks for all the batteries shall be provided. They shall be free standing type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries racks and supports for cable termination shall be coated with three (3) coats of anti-alkali paint of approved shade. Name plates, resistant to alkali, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled conditions, match markings shall be provided to facilitate easy assembly.

3.02.09

Manufacturers Identification System The following information shall be indelibly marked on outside of each cell. (a.) (b.) (c.) Manufacturers name and trade marks Country and year of manufacture. Manufacturer type designation.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-11 BATTERY

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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CLAUSE NO.

TECHNICAL REQUIREMENTS (d.) (e.) AH capacity at 5 hour discharge rate. Serial number

4.00.00

THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION CARDS SUPPLIED WITH THE BATTERY: (a.) (b.) (c.) (d.) Manufacturer's instructions for filling and initial charging of the battery together with starting and finishing charging rate. Maintenance instructions. Designation of cell in accordance with IS:10918. Storing conditions of electrolyte.

5.00.00 5.01.00

TESTS GENERAL (a.) The Contractor shall submit for Owners approval the reports of all the type tests as per latest IS-1146 (for all applicable tests for containers) / IS-10918 (for Ni-Cd Batteries) and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The complete type tests shall be for any rating of battery in a particular group, based on plate dimensions. In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests shall be as per Quality assurance and Inspection table of batteries. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

(b)

(c)

(d)

5.02.00

Commissioning checks. All tests as listed below shall be carried out on sample cell selected at random by the employer at site after completion of installation. (a.) Physical Examination
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-11 BATTERY

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TECHNICAL REQUIREMENTS (b.) (c.) (d.) (e.) (f.) (g.) (h.) Dimensions, Mass & layout MARKING Polarity and absence of short circuit. Air pressure test Ampere - hour capacity Retention of charge Insulation resistance

The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. PART-B: 6.00.00 6.01.00 LEAD ACID PLANTE BATTERY

CODES & STANDARDS All standards, specification and codes of practice, referred to herein, shall be the latest edition including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS Codes Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes : IS : 266 IS : 1069 IS : 1146 Specification for sulphuric acid Specification for water for storage batteries Specification for rubber & plastic containers for lead acid storage batteries. Specification for stationary cells and batteries, lead acid type (with plant positive plates). Specification for sealing compound for lead acid batteries. General requirements and methods of tests for lead acid storage batteries. Specification for synthetic separators for lead acid batteries. Indian Electricity Rules Indian Electricity Acts

IS : 1652

IS : 3116 IS : 8320

IS : 6071

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TECHNICAL REQUIREMENTS Equipment complying with other internationally accepted standards such as IEC, BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. GENERAL TECHNICAL REQUIREMENTS Equipments DC Batteries shall be stationary lead acid Plante positive plate type conforming to IS:1652. For the purpose of design an ambient temperature of 50 degree centigrade and relative humidity of 85% shall be considered. DC Batteries shall be suitable for standby duty. The Batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 2.7 volts per cell maximum and float charged at about 2.2 V/cell: The number of cells for the 220 Volts shall be 109. Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.

6.02.00

7.00.00 7.01.00

7.02.00 7.02.01

Construction Features Containers Containers shall be made of transparent glass, hard rubber, suitable robust, heat resistance, leak proof, non absorbent, acid resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of transparent containers. Float type level indicator shall be provided in case of opaque containers. The stem portion of the float should be long enough to prevent falling of the float inside the container even if there is no electrolyte in the container. The marking for the electrolyte level should be for the upper and lower limits. The material of level indicator shall be acid proof and oxidation proof. Container shall be closed/sealed lid type. Lid and sealing compound shall be non-cracking type. The container made of hard rubber and plastics shall be type tested as per IS : 1146. All type tests shall be carried out for sealing compound as per IS:3116. The pole sealing arrangement should be such that no acid particle gets entrapped due to acid creep as a result of capillary action and it should be possible to remove and refix the sealing to carry out the maintenance.

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TECHNICAL REQUIREMENTS Vent Plugs Vent plugs shall be provided in each cell. They shall be antisplash type, having more than one exit hole shall allow the gases to escape freely but shall prevent acid from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte sample.

7.02.02

7.02.03

Plates The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS: 1652 as applicable. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative post shall be clearly marked.

7.02.04

Sediment Space Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.

7.02.05

Cell Insulator Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on the racks with adequate clearance between adjacent cells. Minimum distance between adjacent cells shall be more than the buldge allowed for two cells in accordance with IS: 1146.

7.02.06

Electrolyte The electrolyte shall be prepared from battery grade sulphuric acid conforming to IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry uncharged. The electrolyte shall be supplied separately.

7.02.07

Connectors and Fasteners Lead or Lead coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent corrosion. The thickness of lead-coating of connectors should not be less than 0.025 mm. The lead coating thickness shall be measured in accordance with APPENDIX F of IS: 6848 (latest edition). All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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TECHNICAL REQUIREMENTS discharge current of the respective Batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same.

7.02.08

Battery racks Wooden racks for all the batteries shall be provided. These racks shall be made of good quality first class seasoned teak wood in line with CPWD specification. They shall be free standing type mounted on porcelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries rack and wooden support for cable termination shall be coated with three (3) coats of anti-acid paint of approved shade. Numbering tags, resistant to acid, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled condition, suitable match markings shall be provided to facilitate easy assembly.

7.02.09

Manufacturers Identification Systems The following information shall be indelibly marked on outside of each cell. (a.) (b.) (c.) (d.) (e.) Manufacturer's name and trade marks Country and year of manufacture. Manufacturer type designation. AH capacity at 10 hour discharge rate. Serial number

8.00.00 8.01.00

TESTS GENERAL The Contractor shall submit for Employers approval the reports of all the type tests as per the latest IS-1146 (for rubber & plastic containers for Lead acid storage batteries) carried out with in the last 10 years from the date of bid opening and the tests should have been witnessed by a client. The complete type test reports shall be for any rating of battery in a particular group, based on plate dimensions being manufactured by supplier.

8.01.01

In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. Routine and acceptance tests shall be as per Quality assurance & inspection table of battery.

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TECHNICAL REQUIREMENTS All routine tests as per QA table and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet. Commissioning checks All tests as listed below shall be carried out on sample cell selected at random by the employer at site after completion of installation. 1) 2) 3) Verification of markings. Verification of dimensions. Test for capacities for 10 hrs discharge rate alongwith the test for voltage during discharge.

8.01.02 8.01.03

8.02.00

The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed requirements the Employer shall have the option of asking the Contractor to replace the same.

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PART - B SUB-SECTION-IIIB-12 BATTERY CHARGER

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

BATTERY CHARGER 1.00.00 1.01.00 CODES AND STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes. ANSI-C 37.90a IS:5 IS : 694 IS : 1248 Guide for surge withstand capability tests

Colours for ready mix paints. PVC Insulated Cable for working voltages upto and including 1100 V. Specification for Direct measuring instruments. acting indicating analogue electrical

IS:13947 Part-1 IS : 13947 IS : 3231 IS : 3842 IS : 3895 IS : 4540 IS:6005 IS:6619 IS:6875

Degree of protection provided by enclosures for low voltage switch gear and control gear. Specification for low voltage switch gear and control gear Electrical relays for power system protection. Application guide for Electrical relays for AC System Mono-crystalline semi-conductor Rectifier Cells and Stacks Mono crystalline semi-conductor Rectifier assemblies and equipment. Code of practice for phosphating of Iron and Steel. Safety Code for Semi-conductor Rectifier Equipment. Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto 1000 V AC or 1200 V DC. Basic environmental testing procedures for electronic and electrical items.

IS : 9000

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TECHNICAL REQUIREMENTS

IS:13703

Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC. Performance requirements for electrical Alarm Annunciation System Indian Electricity Rules Indian Electricity Act.

EEUA-45D

1.02.00

Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. EQUIPMENT DESCRIPTION PART-I (a.) BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY

2.00.00 2.01.00

The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC lead-acid Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 2.25 Volts per cell. All chargers shall also be capable of Boost charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50C. Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging. All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition. Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall neither damage the Charger nor shall it cause blowing of any of the changer fuses. The
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-12 BATTERY CHARGER

(b.) (c.)

(d.)

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TECHNICAL REQUIREMENTS

Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode. (e.) When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3/-5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode. During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type. Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits as mentioned elsewhere, shall be less than fifteen seconds. Momentary output voltage of the Charger, without the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified as mentioned elsewhere in less than 2 seconds after the above mentioned change. The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device. Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery. The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation.

(f.)

(g.)

(h.)

(i.)

(j.)

(k.)

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TECHNICAL REQUIREMENTS

2.02.00

PART-II (a.)

BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY

The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC Nickel-Cadmium Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 1.4 to 1.42 Volts per cell. All chargers shall be capable of Boost charging the associated D.C. Battery at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50C. Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging. All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition. Soft start features shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall not damage the Charger, nor shall it cause blowing of any of the charger fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode. When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3 to -5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode. During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the

(b.) (c.)

(d.)

(e.)

(f.)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type. (g.) Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits as mentioned elsewhere shall be less than fifteen seconds. Momentary output voltage of the Charger, without the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified as mentioned elsewhere in less than 2 seconds after the above mentioned change. The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device. Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery. The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation.

(h.)

(i.)

(j.)

(k.)

2.03.00

Printed Circuits Boards (PCB) PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8% pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge connectors of the PCBs shall be plated with hard gold to a minimum thickness of 5 microns. Component identification shall be printed on PCB by silk screen method. All PCBs shall be tropicalised and masked.

2.04.00

CONTACTORS All Battery Chargers shall have an AC contactor on the input side. It shall be of air break type and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC.

2.05.00

Thermal Overload Relay A thermal overload relay incorporating a distinct single phasing protection (using differential movement of bimetal strips) shall also be provided for the AC input. The relay shall trip the above contactor.

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TECHNICAL REQUIREMENTS

2.06.00

Rectifier-Transformers and Chokes The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier-transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier-transformers and chokes shall have class-B insulation with temperature rise limited to class-A insulation value.

2.07.00

Rectifier Assembly The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with natural air cooling. The rectifier shall utilise diodes/thyristors and heat sinks rated to carry 200% of the load current continuously and the temperature of the heat sink shall not be permitted to exceed 85C absolute duly considering the maximum charger panel inside temperature. The Contractor shall submit calculations to show what maximum junction temperature will be and what the heat sink temperature will be when operating at 200% and 100% load current continuously duly considering the maximum surrounding air temperature for these devices inside the charger panel assuming air ambient temperature of 50C outside the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be provided in each arm of the rectifier connections.

2.08.00

DIGITAL INDICATING INSTRUMENTS Digital indicating instruments with built in communication port for remote data transfer shall be provided for all chargers. The instruments shall indicate DC current, DC voltage & AC voltage and instrument shall be 96 x 96 sqmm, with display accuracy 0.5%, 4 digit 7 segment LED/LCD display and RS 485 serial Bus port.

2.09.00

AIR BREAK SWITCHES All Chargers shall have AC input and DC output switches of air break, single throw, load break and fault make type. The contacts of the switches shall open and close with a snap action. Switches shall be rated for 120% of the maximum continuous load. ON & OFF position of the switch shall be clearly indicated.

2.10.00

CONTROL AND SELECTOR SWITCHES Control and selector switches shall be of rotory stayput type with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction and suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred. The contact ratings shall be atleast the following : (a.) (b.) (c.) Make and carry continuously 10 Amps. Breaking current at 220 V DC 0.5 Amp. (inductive) Breaking current at 240 V AC 5 Amp. At 0.3 p.f.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-12 BATTERY CHARGER

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TECHNICAL REQUIREMENTS

2.11.00

FUSES Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger. Kick-off fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.

2.12.00

Indicating Lamps Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The indicating lamp shall be of panel mounting, filament type low wattage or LEDs and capable of clear status indication under the normal room illumination. The lamps shall be provided with series resistors (non-hygroscopic) preferably built in the lamp assembly and replaceable from front. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat resistant material

2.13.00

Blocking Diode Blocking diode shall be provided in the output circuit of each Charger to prevent current flow from the D.C. Battery into the Charger.

2.14.00

Annunciation System Visual indications through indicating lamps/LEDs or annunciation facia as per EEUA-45D shall be provided in all Chargers for the following: (a.) (b.) (c.) (d.) (e.) (f.) (g.) A.C. supply failure Rectifier fuse failure Surge circuit fuse failure Filter fuse failure Load limiter operated Charger trip Battery on Boost

Potential free NO contacts of all above conditions shall be provided for following remote alarms in the Employers Unit Control Board: (h.) (i.) 2.15.00 Battery on Boost Charger trouble (this being a group alarm initiated by any of the faults other than Battery on Boost)

Name Plates and Marking The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall have black back-ground with white engraved letters and secured by screws. These shall be provided near top edge on the front as well as on rear side of Charger. Name

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plates with full and clear inscriptions shall also be provided on and inside the panels for identification of the various equipments. 3.00.00 3.01.00 CONSTRUCTION The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not less than 1.6 mm and shall have folded type of construction. The panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables shall be made of electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a later date for provision of suitable lugs and gland plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The Chargers shall have hinged double leaf doors provided on front and/or backside for adequate access to the Charger internals. All the Charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be atleast IP42. All indicating instruments, control & selector switches and indicating lamps shall be mounted on the front side of the Charger. Design of panels shall be based on the following dimensions. 1) 2) Overall height Maximum 2350 mm Maximum 1800 mm Minimum 350 mm

3.02.00

Operating handles (highest and lowest positions reached by operators hands), protective mechanical indicators Doors and panel handles and locks -

3)

Maximum 1800 mm Minimum 300 mm

3.03.00

Electronic equipments shall be of modular design consisting of plug in modules in standard 19 inches metallic racks with metallic card guides. The cards should be provided with proper handles. Card to card wiring should be preferably through a mother board. Unplanned jumpering and track modifications are not permitted. Mechanical interlocks to prevent wrong insertion of cards should be provided. Each card shall have its junction and test points identified. Maintenance aids such as extension printed wiring boards and jumper leads shall be provided.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-12 BATTERY CHARGER

PAGE 8 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

3.04.00

The layout of Charger components shall be such that their heat losses do not give rise to excessive temperature within the Charger panel surface. Location of the electronic modules will be such that temperature rise of the location, in no case, will exceed 10C over ambient air temperature outside the Charger. Each Charger panel shall be provided with an illuminating lamp and one 5 Amp. Socket. Switches and fuses shall be provided separately for each of the above. Locking facilities shall be provided as following: (a.) For locking Trickle/Boost selector switch in the trickle position only. This would be used for having key mechanical interlock between Trickle/Boost selector switch and isolator in D.C. distribution board which is being procured separately by the employer. The Charger enclosure door locking requirements shall be met by the application of padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the padlock in position.

3.05.00 3.06.00

(b.)

3.07.00 3.07.01

Wiring Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks ready for external connection. The power wiring shall be carried out with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The control wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5 sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and identification. At least 20% spare terminals shall be provided for circuits. Power and control wiring within panels shall be kept separate. Any terminal or metal work which remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding. An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts should be insulated or shrouded. PAINTING Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with final shade of RAL9002 for complete panel except end covers & RAL 5012 for end covers.

3.07.02

3.07.03

3.08.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-12 BATTERY CHARGER

PAGE 9 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

4.00.00 4.01.00

TESTS GENERAL 1. All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. a) b) c) d) e) Complete physical examination Temperature rise test at full load. Temperature rise test of rectifier assembly at 200% of full load. Insulation resistance test. High voltage (power frequency) test on power and control circuits except low voltage electronic circuits. Ripple content test at i) ii) iii) g) No load Half load Full load

f)

Automatic voltage regulator operation test at specified A.C. supply variations at i) ii) iii) No load Half load Full load

h) i) j)

Load limiter operation test Efficiency and power factor measurement. Input and output surge withstand capability test. Surge Voltage as per

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-12 BATTERY CHARGER

PAGE 10 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

ANSI-C37.90a shall be applied for period not less than 2 sec. At the following points of the Charger operating at 50 deg. C at full load : i) ii) iii) iv) Across each A.C. input phase Across AC input line to ground. Across D.C. output terminals. Across each D.C. output terminal to ground The Charger shall not exhibit any component damage and there shall be no change in performance as per (g) and (h). k) Environmental Tests Steady state performance tests (g) and (h))shall be carried out before and after each of the following tests. i) Soak Test The electronic modules shall be subjected to continuous operation for a minimum period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg. C. The 48 hour test period shall be divided into four equal 12 hour segments. The input voltage during each 12 hours shall be nominal voltage for 11 hours followed by 110% of nominal voltage for 30 minutes, followed by 90% of nominal voltage for 30 minutes. ii) 2. Degree of protection test.

However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.

3.

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SUB-SECTION-IIIB-12 BATTERY CHARGER

PAGE 11 OF 12

CLAUSE NO.

TECHNICAL REQUIREMENTS

4.

The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet.

5.00.00 5.01.00

COMMISSIONING The contractor shall carryout the following commissioning tests and checks after installation of the equipment at site: (a.) (b.) (c.) (d.) (e.) (f.) (g.) Complete physical examination. Checking of proper operation of annunciation system. Temperature rise test at full load. Insulation resistance test. Automatic voltage regulator operation. Load limiter operation. Dynamic response test.

Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100% to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage of the Charger connected with Battery shall be within 94% to 106% of the voltage setting in above conditions and shall return to, and remain, within the limits specified as mentioned elsewhere, in less than 2 seconds (as applicable).

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-12 BATTERY CHARGER

PAGE 12 OF 12

PART - B SUB-SECTION-IIIB-13 CONTROL PANEL

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CONTROL PANELS 1.00.00 CODES AND STANDARDS Programmable Logic Controller 2.00.00 CONTROL TYPE PLC based 3.00.00 3.01.01 PANEL CONFIGURATION Stacker Reclaimer control system Stacker / Reclaimer control desk having necessary push buttons, switches, joy sticks etc. to operate the entire machine shall be provided in two parts, one part on the left side and the other part on the right side of the operator in the operator cabin. OWS shall be mounted in front of the operator so that he can control the machine through key board / mouse also. The other OWS, PLC processor panel and I/O panel along with printer shall be housed in the MCC room on the S/R machine. No remote I/O panel is envisaged in the operator cabin. 3.02.00 Wagon Tippler control system Wagon tippler control desk having necessary push buttons, switches, OWS etc. shall be provided for the wagon tippler system being supplied by the contractor. Operator shall be able to operate the Wagon tippler from control desk as well of from OWS. Remote I/O panels are to be provided in the Control rooms and in the MCC rooms as per the requirement. 3.03.00 Separate, vertical, free standing PLC & RIO panels with Perspex/glass door for visual access to LEDs shall be provided for each stacker reclaimer machine and for each wagon tippler. Power distribution equipment i.e. Control transformers/ UPS/Power Supplies/Backup Batteries/ MCBs etc shall be housed in a separate free standing vertical panels. Local control panels for Coal handling plant: Local control panels for traveling trippers, metal detectors, sump pumps, SM & ILMS, belt weighers and hoists shall be free standing, floor/wall mounting type. They shall be provided with the necessary power equipment like switches, fuses, contactors etc. and the required control equipment like selector switches, meters, push buttons, indications, and annunciations etc. Local control panels shall be provided for Coal sampling units, hydraulic scoop coupling and dust suppression system. However control of these systems shall be through main DDCMIS with starters located in the main MCCs only. IEC: 1131

3.04.00 3.05.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 1 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

Necessary controls, indications and annunciations, as described elsewhere, for all the above equipment shall be provided in main CHP control desk and DDCMIS being procured by the employer under a separate package. 4.00.00 4.01.00 SYSTEM CONFIGURATION Control shall be normally affected through OWS. Facilities to operate HT load break isolator switch of S/R & LT breakers of S/R & WT shall be provided on the respective control desk also. All indicating instruments (i.e. Ammeters/ Voltmeters) shall be digital type and of accuracy class 1. Ammeters shall be provided on control desk for all motors rated 30 kW and above and for I/Cs and B/Cs of LT switchgear. Voltmeters shall be provided on control desk for LT bus voltages. 4.02.00 5.00.00 Ammeters and Voltmeters shall be suitable for 4-20mA DC signals. CONTROL SYSTEM 1). The control system for all the coal handling drives including conveyors, Dust Suppression System, etc except for the Stacker Reclaimer and wagon tippler shall be DCS based being procured by the employer under a separate package. The control system for stacker reclaimer and wagon tippler shall be PLC based. The PLC system shall be provided with 2x100% processors in hot standby mode. Standby processor shall be energised and continuously monitored for healthiness. In case a failure of working processor, the standby processor shall take over the operation automatically by bumpless transfer and necessary failure alarm shall be provided. Both the work stations of a PLC system shall be suitable for operation and also for programming hence software shall be provided accordingly. The processor along with their accessories shall be housed in a free standing vertical type PLC panel separate from control desk. The operation and supervisory system shall consist of PC (latest model), TFT monitors with key boards which shall be mounted as an integral part of the control desk. The processor along with OWS, printer etc. and control panels shall be interlinked through independent dual data highway and dual I/O communication links. The hot standby shall be hardware based and there shall be dedicated link between the two processors for data and program equalization. The push button and selector switches mounted on control desk shall send necessary signals through PLC. The list of required annunciations shall be finalised during detail engineering. Detailed alarms shall be displayed on OWS.

2).

3).

4).

5).

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 2 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

6).

In addition to the controls from the control desk/keyboard/local control panels, each drive shall be provided with local stop push button station near the drive and shall be wired to PLC. The PLC shall provide supervisory information for alarm, various types of displays, status information, trending, historical storage of data etc. and also perform self monitoring and diagnostic functions.

7).

6.00.00

CONTROL PHILOSOPHY 1). Normal / local mode of operation shall be selected from the key board. (a) In normal mode of operation, which shall be the default mode, all drives shall be operated from control desk through keyboard. Whenever required for maintenance, maintenance mode for equipment will be selected through keyboard . Operation interlocks, except trip interlocks shall be locked using a unique password. After maintenance, the drives shall be started through keyboard , with all process interlocks, by re-entering the password. Normal mode of operation can be selected then. Irrespective of any PLC mode of operation, the running equipment can be stopped from keyboard or from desk/panel or from emergency stop push button.

7.00.00

TRAINING Further to the relevant clause regarding training specified elsewhere, Bidder's experienced personnel/engineers shall also provide training courses on offered PLC system to Employer's engineers in the following areas: (a.) (b.) (c.) (d.) Operator training Hardware Maintenance training Software training Any other specialized training as required for system operation and maintenance.

The maintenance training shall include lectures and hands on experience on similar type of equipment / system at manufacturer works and recently commissioned operating plant and / or training simulator. The Owner shall require training of two hardware and two software engineers and the duration of each course shall be minimum two weeks. The details of hardware and software training shall be finalised during detailed engineering and shall be subject to Employer's approval.
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 3 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

8.00.00 8.01.00

PLC EQUIPMENT AND SYSTEM REQUIREMENTS Each PLC system shall consist of redundant processors, PCs with CRT (latest version with latest application software) & keyboard, I/O modules, UPS / power supply with battery backup, printer etc. Each PC based operating and programming workstation shall be fully equipped for operation and control of the various systems. The configuration of PLC shall be as per enclosed drawing. Details of various components shall be as given below : a) b) Processor Memory Two (2) numbers. one as hot standby Non volatile EPROM, Lithium or Ni-Cd battery for 360 hours backup, 20% spare capacity for future use. Normal/Test/Program/Off facility shall be provided. In test mode all outputs shall be blocked. Twenty inches (20 inches) TFT flat monitor with resolution of 1280 x 1024 pixels non interfaced, refresh rate min. 75Hz, with flat membrane type keyboard/ mouse. Provision for erasing and duplicating the user program and long storage facility, forcing facility for changing the status of inputs and outputs, timers and flags to facilitate fault finding and other testing requirements shall be provided. The numbers of OWS shall be as per PLC configuration diagram. Modular design. Possible to change any module without disconnection of any wire. Keying in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. Wiring between I/O cards & terminal blocks shall be through prefab cables. Twenty (20%) percent spare capacity in input output and CPU memory modules shall be provided in each rack over and above system requirement. One additional Ethernet port shall be made available in each PLC system so that wireless communication modem can be connected by the Employer in future. All Output cards shall be sourcing type and Input cards shall be sinking type. 1.5 KV with opto couplers.

c)

Selection

d)

Monitor & Keyboard

e)

Processors & I/O racks

f)

Isolation between Input, Output and controller

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 4 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

g)

Indication

Individual signal status of each Input / Output, power supply status. mode On power supply failure / both PLCs failure / communication failure etc. the output shall be automatically switched over to fail safe mode. In CPU, memory should exist where the sequence was aborted. Further, in case of such failures, operating drives / equipment shall be tripped or kept running as per a pre-determined programmable requirement finalised during detail engineering. Individual fuses with blown fuse indicator for each output. Individual fuses for each input/ group of inputs, keeping in view of system availability. Output modules shall be rated to switch on/off coupling relays of 2.5 VA at 24V DC and solenoid valves at 110 V AC. Coupling relays are provided in HT/LT Switchgears. Hundred percent redundant Communication links through routed in separate GI conduits.

h)

Fail

safe

i)

Fusing philosophy

j)

Switching capacity

k)

HMI/CPU and Input output communication links Printer

l)

Color laser printer shall be suitable for A4 size paper, 4 pages per minite, 600 dpi (black) and heavy duty(>_ 30000 pages per month) Number of printers shall be as shown in the tender drawing PLC Configuration.

m)

Power supply

i)

Two (2) nos 415V AC feeders shall be provided for each control panel / desk and remotely located I/O panels. Power supply to stacker reclaimer control system i.e., PLCs, I/Os, printer, OWS, and control desk shall be fed through 2x100% UPS with battery back-up rated for 30 minutes at full load. The UPS shall be smart type line interactive complete with software & hardware for remote management along with features of surge suppression & AVR facility. The UPS and batteries shall be rated for 20% spare capacity. Redundant DC power packs shall be provided for DC loads.

ii)

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 5 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

iii)

Power supply to Wagon tippler control system shall also be same as given for stacker reclaimer as indicated above.

iv) All the batteries shall be sealed maintenance free NiCd type. n) Command hierarchy Manual command shall prevail over auto command. Protection command shall have priority over all other commands. Hundred percent redundant. Necessary interface hardware and software for dual fibre connectivity and interconnection with employers DDCMIS for two way transfer of signals through OPC compliant Ethernet link following TCP/IP standards. To be synchronised with DDCMIS

o)

Databus

p)

Time Synchronisation system. Date Insensitivity System reaction time Display response Feedback/field interrogation

q)

No disturbance due to change of date/year.

r)

Less than 100 msec. from input signal to output signal including logic processing. Max 1 sec for control related displays. 2 to 3 sec for other displays. By 24V DC. Status feedback from MCC/field shall be in the form of one changeover contact. Discrepancy shall be alarmed. All analog signals shall be routed through analog cards. Flow chart/Block logic ladder diagram. Tag based addressing format shall be used for programming. The same shall be submitted for owner's review before programming of the system. 168 hours latest data on hard disc. Data to be stored:

s)

t)

u)

Programming format

v)

Long time storage & retrieval i) ii)

Alarm list. Five analog points at scan rate.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 6 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

iii)

Fifteen analog points at one secs rate.

iv) Balance analog points at 5 minutes rate. v) vi) w) Software Binary points on status change. Log reports. All application software with locks and passwords for PLC functioning like input/output scanning, acquisitions, condition processing, control and communication, operator interface of monitors, display trends, curves, bar charts, historical storage/ retrieval and alarm functions. Complete set of documents for modifications / editing / additions/ deletions of features in software. Comprehensive list of all application/system software. Industrial grade furniture shall be provided along with Control desk/OWS/printer. The contractor shall provide software license for all software being used in PLC based control system including HMI. The software licenses shall be provided for the project and shall not be hardware/machine specific. All licenses shall be valid for the continuous service life of the plant. As a customer support the contractor shall periodically inform the designated officer of the employer about the software upgrades / new releases that would be taking place after the system is commissioned so that if required, same can be procured and implemented at site.

x)

Accessories

y)

Software license

z)

Software upgrades

8.02.00

Annunciation System i) ii) Facia Operation On occurrence of trouble Acknowledge button pressed Translucent glass/plastic window with engraving. Through PLC. Audible horn and flashing of facia lamp.

a) b)

Audible horn and flashing of facia lamp shall stop. Facia lamp will become steady.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 7 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

c)

Reset button pressed Test button pressed Monitoring

If fault is removed then facia lamp will go off.

d)

All lamps will glow.

iii) 9.00.00

Power supply to annunciator shall be monitored.

DESK/PANEL CONSTRUCTION a) Type Fabricated from cold rolled sheet steel Frame thickness 2.0 mm

Enclosure thickness 1.6 mm Gland plate thickness 3.0 mm b) c) d) Switches Fuses Name Plates & Labels AC22 category HRC cartridge with visual operation indicator. Each panel shall be identified by a name plate. Panel internal equipment shall be identified by paint marking. Nameplates shall be non rusting metal or 3-ply lamicoid, with engraved lettering and shall be subjected to Owners approval. 25 x 3 mm copper ground bus to be provided for each panel 240V AC, single phase, thermostatically controlled space heaters to be provided. 650V grade. clip-on type. Elmex - CATD type for CTs. Elmex - CSLT for other application. 20 percent. 650V grade. PVC insulated stranded copper wire. Each free standing panel shall be provided with a door switch operated fluorescent lamp and a 240V AC plug point. Treatment as per IS: 6005. Two coats of lead oxide primer followed by powder painting with final paint shade of RAL 9002.

e)

Grounding

f)

Space heater

g) h)

Terminal block Type

i) j) k)

Spare Wiring Panel Lighting

l)

Painting

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 8 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

m)

Degree of enclosure protection

For panels located in i) Air conditioned areas ii) Other indoor areas iii) Outdoor areas iv) Dusty areas like Conveyor galleries, Transfer points, Bunker area, Track hopper area, Crusher house etc. : IP-32 : IP-52 : IP-55 : IP-65

10.00.00 10.01.01

TYPE TESTS All equipment to be supplied shall be of type tested quality. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. In case the Contractor is not able to submit report of the type test(s) conducted within last five years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract free of cost to the Owner and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. Programmable logic controller Following test reports shall be submitted for the equipment: a). b). c). d). e). f). Dry heat withstand test Variation of temperature immunity test Variation immunity test Temperature cycle test Noise immunity test Dielectric test.

10.01.02

10.01.03

10.02.00 10.02.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 9 OF 10

CLAUSE NO.

TECHNICAL REQUIREMENTS

10.02.02

Following tests shall be conducted under this contract as routine tests: a). b). c). d). e). Tests on internal and external wiring. Incoming power supply voltage and frequency variation test. Test for verification of functional characteristics of I/Os. Task transition test (for each task, the contractor will list out the user accessible conditions which shall be used in the simulation of the task). Functional testing of software and hardware in accordance with the approved block logic diagram with simulation of the system with switches, relays and solenoid valves etc. or equivalent loads.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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SUB-SECTION-IIIB-13 CONTROL PANEL

PAGE 10 OF 10

PART - B SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CLOSE CIRCUIT TELEVISION SYSTEM (CCTV) 1.00.00 1.01.00 GENERAL REQUIREMENTS The intent of the specification is to define the functional & design requirements for the CCTV System meant for gathering video information from the various operational areas of the Coal Handling Plant. The Contractor shall be responsible for selection, design, engineering, manufacture, testing at manufacturers works/site, installation and commissioning of the system to the satisfaction of Employer. All the cables, cable trays, power packs, erection hardwares etc. are also included in contractors scope. The Contractors scope shall also include successful demonstration of performance testing specified herein complete in all respects alongwith cables, cable trays, junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands, lugs, conduit sleeves, etc., as required, to complete the proper installation conforming to IS:1881, IS:1882 of all the equipments supplied as covered in this specification. All equipment, accessories and facilities required for completeness of this system are included in Contractor's scope, whether these are specifically mentioned herein or not. The CCTV System offered by the Contractor shall be from reputed manufacturer who should have designed, manufactured, tested and commissioned a distributed type CCTV systems as specified in any coal handling plants or any large industrial installation as on the date of bid opening. All major equipment such as Cameras, Video Switcher/Control System, Key Boards, Receiver Drivers, Pan Tilt Units, Post equalisation Video amplifiers, Digital Video Recorder, (DVR) Archiving System etc. shall of the same make. In case the bidder wants to offer Dome type cameras for all applications are also acceptable. The system and all the equipment shall conform to the latest edition of Indian / International and CCITT standards as applicable. The Contractor shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. The design and manufacture shall be such that equipments/components of same type and rating shall be interchangeable. All the cameras shall be connected to a central redundant microprocessor based video switcher/control system to be located in CHP control room. Any other equipment, module required for the safe and satisfactory operation, control, protection, monitoring, testing and maintenance of the system are also included in Contractor's scope. POWER SUPPLY ARRANGEMENT The Contractor shall provide power to the CCTV System from UPS system for microprocessor based switching / control unit, monitor, digital video recorder, etc. in the control room.

1.02.00

1.03.00

1.04.00

1.05.00

1.06.00

1.07.00

2.00.00 2.01.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

PAGE 1 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS DESIGN AND TECHNICAL REQUIREMENTS The CCTV system shall be able to provide surveillance of different locations of the plant. The system shall comprise of Redundant Switcher/Control System capable of controlling Microprocessor based Video

3.00.00 3.01.00

3.02.00

16 nos. of Cameras for Zoom, Pan/Tilt, Multiple pre positionsand auxiliaries 1 2 1 no. of digital video recorder. Multiplexer

Required no. of 21 colour TFT monitors with key board for controlling both manually and automatically and all other accessories required to provide best quality video with controls for making the system complete. It shall be possible to view the CCTV out put on the large video screen also.

3.03.00

The system operation would be of covering the complete view of the areas with pan / tilt, zoom, propositioning of the cameras and with programmability to monitor any camera or number of cameras at a time on any monitor either manually or automatically in a defined switching. The system shall be suitable for installation and shall be able to work successfully in Coal dusty environment. The system shall have the following facilities: a) b) c) d) e) f) g) h) i) Zooming Pan control Tilt control Computer interface Logging printer part Multiple prepositions SALVO switching Programmability Alarm interface

3.04.00

3.05.00

The system supplied shall be complete in all respects for reliable performance. The Contractor shall submit the details block schematic, video, signal & power wiring diagram, describing the connections between the Microprocessor based Video Switcher/Control System and various cameras, pan tilt, receiver driver units, monitors, DVR and keyboard. Programming required shall be done by the Contractor for satisfactory operation.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV) PAGE 2 OF 9

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS The system should be completely compatible to be integrated to Fire Alarm System. When the fire is detected by a particular detector the camera assigned should automatically focus the site of the fire. The video switcher/control system shall permit the design of a distributed matrix video switching system with control at one central location and individual control at the local sites. The main control site could view/control local cameras plus cameras located at any of the remotely distributed sites. DETAILED DESCRIPTION OF THE SYSTEM COMPONENTS : Microprocessor based Video Switcher/Control System The Video Switcher/Control System shall be Redundant, Microprocessor based and modular in construction. It should offer full matrix switching capability, i.e., the system should be programmable to display the video from any camera or number of cameras at a time on any monitor, either manually or via independent automatic switching sequences. The Video switcher/Control System should have provision for minimum 32 camera inputs 2 monitor outputs, keyboards, Digital video recorders, 32 direct connect alarm input points, an integral signal distribution unit, a computer interface port, and a logging printer port including all other hardware / software. The Video Switcher/Control System should be programmable with up to 30 sequences, which can run independently of each other in either forward or reverse direction. Any of the sequences should utilise the Salvo Switching capability where any number of system monitors may be selected to switch as a group. The video switcher/control system should have easy provision for integral signal distribution ports, connections to on-site receiver/drivers. It should have built-in alarm interface capability, any monitor or group of monitors could be set to display cameras under alarm conditions. In addition, 16-character alarm title could be selected to appear instead of the camera title during alarm conditions. The video switcher/control system should include on screen display for time-date, camera number, camera Id, and monitor or status information. The system should have provision for logging printer output port to provide permanent record of system status showing time and date of changes such as : incoming alarms, acknowledgement of alarms, loading of sequences, user log-on to key- board, transfer of system tables and sequence, video loss messages, and a power up reset message, so that a hard copy of the systems configuration tables and sequences can be obtained. The system shall also have the following provisions. User friendly spreadsheet format providing the ability to enter camera titles, operator names, timely events, change system parameters, program camera sequences and install lockouts.

3.06.00

3.07.00

4.00.00 4.01.00 4.01.01

4.01.02

4.01.03

4.01.04

4.01.05

4.01.06

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

PAGE 3 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS It should provide high performance programming, control and monitoring of all the system functions by using on-screen icons to reflect real time status of the devices being controlled by the system. Software should also provide the ability to monitor system status events. System alarms, switching functions, sequence events, keyboard actions, and video loss information. All the video switcher/control system shall be connected to a 10/100 Base Fiber Optic full Duplex Ethernet network, to be provided by the Contractor. In case it is the standard practice of the Contractor to provide PC based video switcher / control system to achieve all the above functions, the same is also acceptable. Keyboard : Keyboard should have full function used for system control and programming and should be ergonomically designed. It should include integral pan/tilt joystick and zoom lens controls. This would be connected to the video switcher/control system for signal and power. Keyboard shall have full function used for system control and programming for selection of various video switcher/ DVR / camera functions including pan/tilt and zoom lens controls and shall be ergonomically designed. The Key board shall be able to access DVR and video switcher. Incase it is the standard practice of the contractor to offer PC based integrated keyboard and monitor, then the same is also acceptable, subject to Employers approval. Cameras : The cameras shall be rugged, 1/4 inch image format, full performance color CCD cameras. These cameras should provide high resolution and high sensitivity suitable for operation in a coal handling plant, both in natural and artificial lighted areas. The cameras should have features as mentioned below : Suitable for night-time surveillance Manual or Automatic colour/infra red switching Automatic picture enhancement to give a balanced picture where there is too little/too much light Remote camera setup, with on screen menu display. Character generator giving up to 24 character text-in-picture. Backlight composition Automatic white balance, with mode selection options Contour correction and contrast compression control.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV) PAGE 4 OF 9

4.01.07

4.02.00 4.02.01

4.02.02

4.03.00 4.03.01

4.03.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS Synchronisation selection for Gen lock, external V-lock, mains lock and internal free-running. All cameras shall be network compatible.

4.03.03

Detailed technical specifications are as under : Imager : Interline transfer CCD, 1/4 inch image format Horizontal resolution : 480TVL in PAL B mode Sensitivity (at f1/4, 6dB), scene illumination 0.7 lux (at 50 IRE color) Light Range Signal-to-noise : > 50dB. AGC : Upto 18 dB Shutter Speed : 1/50-1/1,00,000 LUX. Auto select Lens Mount : Video Iris Gamma Correction : 0.45/1.0 Auto-black contour correction : Colour Contrast compensation : 2.5x Power Supply : 230V AC

4.04.00 4.04.01

Lens : The lens should be Auto-iris lens of 1/4 inch to be mounted on the above camera. It should be zoom lens with CS-Mount. The details are as under: Focal Length : 6 90 mm zoom lens (approx.) Iris range : 1.2 to 360

4.05.00 4.05.01

Camera Housing All the cameras and accessories are to be housed in Weather Proof (IP-65) environmental housing made of aluminum. The housing with heater and blower installed should provide protection for camera/lens assemblies in the ambient temperature range of - 0 deg. C to 60 deg. C. The housing should also have thermostatically controlled heater kit, continuous duty blower kit, purge air arrangement and Window wipers available within the housing. Complete assembly including camera shall be suitable for hot and highly polluted environment of Coal Handling Plant.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

4.05.02

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

PAGE 5 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS Pan & Tilt Unit : The Pan & Tilt unit should be weather proof (IP-65) with pan/tilts designed to meet the rigorous requirement and should be constructed with corrosion resistant hardware. They should be capable of handling loads up to 10 kg and should be having 100% duty cycle motors to permit continuous operation. The pan & tilt should comply with the following : - Electrical 230V AC, 50 Hz - Pan range : 120 deg movement in horizontal plane. - Pan speed : 6 deg./sec. - Tilt : +3 deg to 90 deg movement in vertical plane - Tilt speed : 3 deg./sec. - Construction : Cast aluminum base and yoke, corrosion resistant cover.

4.06.00 4.06.01

4.06.02

4.06.03

4.07.00 4.07.01

On-site Receiver/Driver Unit : The on-site receiver/drive unit should be able to control the motor drives for pan/tilt and cameras for zoom and aux control. These would be used in conjunction with the Microprocessor based video switcher/controller systems. The on-site receiver/driver unit should have features like focus/zoom/iris controls, 99 prepositions lockable enclosure latches, an integral local test function and IP 65 rated environmental enclosure. The On-site receiver/driver unit should be operated from 230V AC, 50 Hz and provision to be within hazardous are in the vicinity of the camera and pan tilt unit. The cable from the receiver drive unit to the pan/tilt unit and the camera is to be provided with the receiver driver unit. Monitor & Key board: The monitors should be colour video monitors that the versatile and attractive units to be mounted on the wall/desk. It should have built in audio. Monitors are to be operable at 230V AC, 50 Hz. They should comply to the following specifications. General : Automatic degaussing, Fast warm up time Display tube : 51 cm diagonal, 90 deg deflection, integral implosion protection. Resolution : 450 TVL minimum

4.07.02

4.07.03

4.08.00 4.08.01

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

PAGE 6 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS Controls : Colour system select, volume, colour, brightness, contrast, power, video input select and Y/C termination.

4.09.00

Digital Video Recorder: Parameter Horizontal Resolution Color system Recording system Recording speed Inputs Specification 720x570 lines PAL/ NSTC, compatible with the CCTV system being proposed by the contractor. Applied JPEG, MPEG, Wavelet or better with Motion detection-Hi performance system. 1-50 frames per second ( fps) , programmable 16 channel with Inbuilt Multiplexer and storage for minimum eight days on HDD for all the connected camera signals. Date, hours, minutes and seconds. Minimum range from 5 sec. To 3 min, to be finalised during detailed engineering stage. Compatible with the finally selected cameras/ network Multiple, 2x2, 4x4, single to be finalised during detailed engineering stage. Manufacturers standard By date, time or cameras Minimum 8. 1V p-p 75 Ohm to be finalised during detailed engineering stage. 1 V p-p 75 Ohm to be finalised during detailed engineering stage. Minimum 5 User Customizable Zones per camera The recorder shall be fully compatible with any standard 10/100 Base FO full Duplex Ethernet port for networking to a central DVD or AIT or Hard Disk Arrays after seven days of recording is over on the HDD. All or selected portions of the recorder material shall be shifted on to AIT or DVD and archived. The Archiving unit shall be common for the stations.

Characters generation Record time by alarm Input signal View Power supply Search Alarm Inputs Video I/P Video O/P Zones Archiving

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

PAGE 7 OF 9

CLAUSE NO.

TECHNICAL REQUIREMENTS In case the contractors standard practice is to provide Digital video recorder which integrates the function of video switcher / controller, then the same is also acceptable. In that case, the DVR shall record multiple camera signals while simultaneously providing live multiscreen viewing and playback. The images per second rate and image quality shall be selectable for each connected camera. The digital recorders shall allow selectable frames per second (fps) record rates from zero fps to minimum twenty five fps. DVR shall also have features: on screen display which records time, date, number of alarms etc Post Equalisation Video Amplifier : The post equalisation video amplifier should provide of controls of adjustable overall gain and frequency boost while maintaining full video amplitude, contrast and detail. It should work on 230V AC, 50Hz. The post equalisation video amplifier should comply to the following : Gain : adjustable from 1 dB to +8 dB Frequency response : Adjustable from flat (+/- 1 dB) at 12 Mhz to greater than +18 dB at 12 Mhz. Controls : Gain, HF boost, LF boost and indication of red LED when power is on.

4.09.01

4.09.02

4.09.03

4.10.00 4.10.01

4.10.02

5.00.00

OPERATIONAL REQUIREMENTS : The CCTV system should comply to the following operational requirement. 1. From the master control panel(keyboard) it shall be possible to select any camera and display the picture on any of the monitors. Commands from the video switcher/control unit is sent via a onsite receiver/drive unit to the camera which in turn controls the pan/tilt zoom etc., functions. Operator shall be able to control all the cameras, pan / tilt and zoom functions manually. The video recorder shall record the activities of all the places where alarm have been alerted. The time-lapse video recorder shall be able to record up to 720 hrs without reloading.

2.

3.

4.

6.00.00 6.01.00

CABLES : Power, control and instrumentation cables shall conform to the relevant section of this specification. Any special cables for use in CCTV shall conform to the relevant Indian/International standards. However all cables shall be FRLS type as specified elsewhere.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV) PAGE 8 OF 9

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

CLAUSE NO.

TECHNICAL REQUIREMENTS All the cables shall be installed as per the requirements stipulated in the relevant sub-section of this specification. The signal / Video transfer from Cameras to the main control room equipment shall be through fibre optic cable Tentative location of 16 nos. of CCTV cameras: Wagon tippler area Crusher house TPs TOTAL 6 nos. 3 nos. 7 nos. 16 nos.

6.02.00

6.03.00

7.00.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIB-14 CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

PAGE 9 OF 9

NTPC Limited
(A Government of India Enterprise)

VINDHYACHAL SUPER THERMAL POWER PROJECT STAGE-III (2X500 MW)

SECTION VI
TECHNICAL SPECIFICATIONS FOR WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

(BOOK 2 OF 2) (CIVIL/QA&I/GTR/ECC/SPARES)
BIDDING DOCUMENT NO. : CS-2240-155C-2

NTPC Limited
(A Government of India Enterprise)

VINDHYACHAL SUPER THERMAL POWER PROJECT STAGE-III (2X500 MW)

SECTION VI
TECHNICAL SPECIFICATIONS FOR WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

(BOOK 2 OF 2) (CIVIL/QA&I/GTR/ECC/SPARES)
BIDDING DOCUMENT NO. : CS-2240-155C-2
(This document is meant for the exclusive purpose of bidding against this Bid Document No. / Specification and shall not be transferred, reproduced or otherwise used for purposes other than that for which it is specifically issued).

TABLE OF CONTENTS

TABLE OF CONTENTS
PART SECTION NO TITLE

BOOK 1 OF 2 : MECHANICAL & ELECTRICAL PART-A Sub Section- I Project Synopsis

Sub Section II : Scope of Supply & Services Intent of Specification IIA-01 PART-A Terminal Points & Exclusions IIB-01 IIC-01 PART-B PART-B PG Test Procedure Spares Scope

Sub Section III : Technical Parameters III-A IIIA-01 MECHANICAL System Parameters and Operation & Control Philosophy Wagon Tippler Brakes & Clamps Monorails and Hoists Chutes & Hoppers Belt Conveyor System Drive Equipment Belt Scale Dust Control & Miscellaneous System Ventilation System CHP Building Vibrating Screening Feeder Ring Granulator and VMS

IIIA-02 IIIA-03 IIIA-04 IIIA-05 IIIA-06 IIIA-07 IIIA-08 IIIA-09 IIIA-10 IIIA-11 IIIA-12 IIIA-13
VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

MAIN CONTENTS

PAGE 1 OF 3

TABLE OF CONTENTS

PART

SECTION NO IIIA-14

TITLE Inline Magnetic Separator and Suspended Magnet Metal Detector Coal Sampling Unit Elevator Apron Feeder Side Arm Charger ELECTRICAL Motors LT Switchgear & Bus Duct HT Cables LT Power Cables Control Cables Instrumentation cables Illumination System Cabling, Earthing & Lightning Protection Transformers HT Switchgear Battery Battery Charger Control Panel Closed Circuit Television System (CCTV)

IIIA-15 IIIA-16 IIIA-17 IIIA-18 IIIA-19 PART-B PART-B III-B IIIB-01 IIIB-02 IIIB-03 IIIB-04 IIIB-05 IIIB-06 IIIB-07 IIIB-08 IIIB-09 IIIB-10 IIIB-11 IIIB-12 IIIB-13 IIIB-14

BOOK 2 OF 2 : CIVIL / QA&I / GTR / ECC / SPARES PART-B PART-B III-D IIID-01 CIVIL CHP System - Civil & Structural Works

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

MAIN CONTENTS

PAGE 2 OF 3

TABLE OF CONTENTS

PART

SECTION NO IIID-02

TITLE Foundation System and Geotechnical Data (Turnkey) QA & I SECTION Coal Handling Plant Motors LT Switchgear & Busduct LT Power Cables LT Control Cables Instrumentation Cables Station Lighting Cabling, Earthing & Lightning Protection Control Panels Programmable Logic Controller (PLC) Battery Charger HT Cables HT Switchgear Actuators Auxiliary Transformer Battery & Battery System Measuring & Instrumentation Closed Circuit Television System (CCTV) CHP System - Civil & Structural Works General Technical Requirements Erection Conditions of Contract List of Tender Drawings List of Mandatory Spares

PART-B

III-E IIIE-01 IIIE-02 IIIE-03 IIIE-04 IIIE-05 IIIE-06 IIIE-07 IIIE-08 IIIE-09

PART-B

IIIE-10 IIIE-11 IIIE-12 IIIE-13 IIIE-14 IIIE-15 IIIE-16 IIIE-17 IIIE-18 IIIE-19

PART-C PART-D PART-E PART-F

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

MAIN CONTENTS

PAGE 3 OF 3

CIVIL WORKS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

PART - B SUB-SECTION-IID-01 CIVIL WORKS

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

CLAUSE NO.

TECHNICAL REQUIREMENTS

CONTENTS CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 GENERAL LAYOUT & LEVELS DRAWINGS/DOCUMENTS WORK DESCRIPTION 4.01.00 Wagon Tippler, Machinery Hatches and Underground Tunnel 4.02.00 - Overhead / Ground Conveyor Galleries and Trestles 4.03.00 Transfer Houses 4.04.00 Crusher House 4.05.00 Control Buildings, MCC Buildings 4.06.00 Pump Houses 4.07.00 Pent House 4.08.00 Toilets 4.09.00 Staircases 4.10.00 Trenches 5.00.00 Drainage & Water Supply Works 5.01.00 Drainage System 5.02.00 Internal and external water supply, drainage 6.00.00 7.00.00 8.00.00 9.00.00 COLOUR COATED AND OTHER SHEETING WORK ROOF DETAILS FLOOR AND GRADE DETAILS BRICKWORK & ALLIED MASONRY WORKS DESCRIPTION

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 1 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS

10.00.00 11.00.00 12.00.00 13.00.00 14.00.00 15.00.00

EARTHING MAT FENCING LOADING DESIGN CRITERIA CONCRETE EXCAVATION DETAILS 15.01.00 Excavation in soil 15.02.00 Excavation in rock 15.03.00 Dewatering of deep foundations 15.04.00 Backfilling, disposal & stacking of materials

16.00.00 17.00.00 18.00.00 19.00.00

Galvanising Chemical Injection Grouting Polymer modified cementitious coating Architectural Features 19.01.00 Glazing 19.02.00 False ceiling 19.03.00 Acid/Alkali Resistant Lining 19.04.00 Finishing Schedule 19.04.01 Flooring 19.04.02 Interior wall/ ceiling finish 19.04.03 Exterior finish 19.05.00 Door, windows & rolling shutters 19.05.01 Doors & Windows 19.05.02 Rolling Shutters

20.00.00

Painting

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 2 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS

21.00.00 22.00.00 23.00.00 24.00.00 25.00.00 26.00.00 27.00.00 28.00.00 29.00.00 Annexure A

Miscellaneous Shotcreting Vibration Isolation System Packaging & Transportation Plant Life PTFE Bearing Tests for Materials/Workmanship Materials Codes and Standards Criteria for Earthquake Resistant Design of structures & Equipment Criteria for Wind Resistant Design of structures & Equipment

Annexure B

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 3 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS GENERAL This section of the bidding document deals mainly with the technical specification needed for the design and preparation of detailed drawings, getting the design and drawings approved by the Engineering, fabrication, erection and construction of the necessary civil, structural and architectural works associated with the coal handling plant to be installed at VINDHYACHAL STPP. 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 Coal Handling Plant. The specifications are intended for the general description of the work, quality and workmanship. The specifications are not, however, intended to cover minutest details and the work shall be executed according to the relevant latest Indian Standard Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be executed according to the best prevailing local Public Works Department practices or to the recommendations of relevant American and British Standards or to the instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the Technical Specifications. The Contractor is expected to get clarified on any doubts about the specifications, etc. before bidding, in writing with the Employer in respect of interpretation of any portions of this document. The civil and steel structural design for the works under the scope of this contract shall be carried out by an agency who should have designed the following works within the preceding seven (7) years, reckoned as on date of bid opening. (1) The civil & steel structural works associated with at least one bulk material handling plant. The civil & steel structural works associated with structures like track hopper, wagon tippler, underground tunnels, etc.

1.00.00 1.01.00

1.02.00

1.03.00

(2)

The bidder may engage a consulting agency which meets the above requirements for design, either in same or separate contracts. The bidder is required to furnish in the bid documents, details regarding the design experience of himself or the consulting agency engaged by him, meeting the above requirements. The consulting agency proposed by the bidder for design shall be subject to Owners approval. 2.00.00 2.01.00 LAYOUT AND LEVELS The layout and levels of all structures, etc. shall be made by the Contractor at his own cost from the general grid of the plot and bench mark given by the Engineer. He shall provide all instrument, materials and men to the Engineer for checking the layout and levels. However, the Contractor shall be fully responsible for correctness of layout and levels.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 4 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS DRAWINGS / DOCUMENTS The drawings included in the Bidding Document provide a general idea about the work to be performed under the scope of this contract. These are preliminary drawings for bidding purposes only and are by no means the final drawings or show the full range of the work under the scope. Work has to be executed according to drawings prepared by the contractor and approved by the Engineering. Conceptual arrangement of civil works supported by calculations shall be submitted along with tender bids. Later on, detailed construction drawings and design calculations for all civil works for static as well as dynamic analysis (wherever essential) shall be submitted for approval prior to undertaking construction work. Design calculations shall be done in STRAPP / M.S. Office (latest version) and Drawings shall be prepared in Auto Cad (latest version). The analysis shall be done by using STADD PRO / ANSYS / STRAPP (latest version). However design may be carried out by manually, using computer work sheets or by using suitable software programmes, as mutually agreed by Employer. Final calculations and drawings shall be submitted in Compact Disc (CD) (2 Sets) Civil Task drawings indicating various equipment loading and supporting arrangement and floor loads shall be submitted along with design calculations. Soft copies of all STAAD input files shall be submitted along with the design calculations for all revisions. Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works shall be submitted structure wise and area wise for N.T.P.C. record. However each drawing shall indicate approximate quantity of structure (Sectionwise) Concrete (Grade wise) and reinforcement (Diameterwise.) Structural steel fabrication drawings to be prepared by the contractor will not be approved by the Employer. However, the Contractor for Employers reference shall submit all fabrication drawings. Copy of detailed bar bending schedule as prepared by contractor shall also be submitted to the Engineering and also to Engineer in charge for the reference. Approval of construction drawings prepared by the contractor shall not relieve the Contractor of his responsibility regarding the adequacy of design and correctness of the drawing. WORK DESCRIPTION It includes the Civil, Structural and Architectural works related mainly to the following areas (but not limited to):

3.00.00 3.01.00

3.02.00

3.03.00

3.04.00

3.05.00

3.06.00

3.07.00

4.00.00

4.01.00

Wagon Tippler, Machinery Hatches and Underground Tunnel Wagon Tippler and machinery hatches shall consist of underground portion, which shall be of R. C. C.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 5 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS 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, the beams and top of coal tray in the Wagon Tippler structure 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 shown in the tender drawing. 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. Detailing of expansion joints shall be as per details in the tender drawing. 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 coal slurry setting tank. Side drains and sump shall have removable type steel grating cover. Gratings shall be galvanized to grade 610 gm/m2. Water proofing / Damp proofing of under ground portion of Wagon tippler, tunnels, underground (i. e. 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: (1) On the outer surface of walls, frames and roof slabs coming in contact with earth, polymer modified cementitious coating in two layers as specified and as per manufacturers specifications shall be provided directly on the concrete surface. 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 cementitious coating in two layers ( slurry mix application) as per manufacturers specification. 50 mm thick 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.

(2)

Steel gratings of mesh size 350mm square for wagon tippler hopper shall be provided. The grating shall be built of min. 200mm x 28mm thick flats in main direction and min. 100mm x 20mm thick in secondary direction. The hopper and gratings shall be designed for movement of front end loader/ bulldozer over them. Bull-dozer weight shall be considered as about 35T. No painting/galvanization shall be provided in gratings. However, two coats of Red oxide Primer to be provided immediately after fabrication.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 6 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Plinth protection along with drains shall be provided around the Wagon Tippler. However, 5m wide paving shall also be provided around Wagon Tippler. Earth pressure to be considered for design shall be due to earth pressure at rest (Ko) 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 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 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 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 10o, R. C. C. steps shall be provided for the entire width of each walkway.

4.02.00

Overhead / Ground Conveyor Galleries and Trestles Overhead conveyors shall be located in a suitably enclosed gallery of structural steel. The overhead gallery shall consist of two vertical latticed girders having rigid jointed portal frame at both ends. Cross beams at floor level supporting conveyor stringer beams shall be made of single rolled steel beam or single channel section (ISMB or ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of the gallery (latticed girders shall be braced together in plan at the top and bottom). Common end portal frame shall not be used for adjacent conveyor spans. Roof truss shall be provided at upper node points of latticed girders to form an enclosure. The maximum span of overhead gallery shall be limited to 25 meters unless higher span is required due to site conditions, which shall be subject to approval of the Engineer. The gallery should as far as possible be erected as a box section keeping all the vertical and horizontal bracing tied in proper position. The gallery should be checked for all erection stresses that are likely to develop during handling and erection and if required, temporary strengthening of gallery members during erection shall be made. Seal plates under the conveyor galleries shall be provided in such a way that complete gallery bottom shall form a leak proof floor. The ground conveyors shall be located in suitably enclosed gallery of structural steel consisting of rigid portal frames spaced at regular intervals and suitably braced. Plinth protection along with drains shall be routed along the ground conveyors. For double stream conveyor gallery, two side and one central walkway of clear width 800 mm and 1100 mm respectively shall be provided. The clear width of two side

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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PAGE 7 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS walkways for single stream conveyor gallery shall be 800 mm and 1100 mm respectively. Both sides of central and side walkways shall be provided with pipe handrails all along the conveyor gallery. Hand railing should not be supported on conveyor supporting stringers. The walkways shall be chequered plate construction with anti - skid arrangement. The anti - skid arrangement will consist of welding of 10 mm square steel bars at a maximum spacing of 500 mm along the length of the gallery. Where the slope of walkway is more than 10o, chequered plate steps with nosing and toe guard shall be provided. The floor of conveyor gallery all along the gallery length, shall be provided with minimum 12 gauge thick seal plates and other drainage arrangements as specified elsewhere Conveyor gallery shall have permanently colour coated steel sheet covers on roof and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 6.0 m center shall be provided with translucent sheets of polycarbonate material for natural lighting. A continuous slit opening of 500 mm shall be provided on both sides just below the roof sheeting. Adequate provision of windows shall be kept on both sides of conveyor gallery as appended in Mechanical Section (Belt conveyor system). Windows shall be provided with wire mesh as specified elsewhere in this specification. Cross - over with chequered plate platform and ladder for crossing over the conveyors shall be provided at approximately every 100 M intervals of conveyor. Crossover shall preferably be located over four-legged rigid trestle location. For railway tracks passing below overhead conveyor gallery and along conveyors, the railway clearances both underground as well as over ground shall have to be adhered to for design, execution and erection of foundations, trestles, galleries etc., so that movement of locomotives and wagons is not hampered in any way during execution and afterwards. However at the location where the overhead conveyor gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail top shall be provided. For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be used to take care of inertia force, casual over burden and impact factor etc. Thus coal load per unit length of each moving conveyor shall be 1.6 X Rated Capacity of Conveyor system -----------------------------------------------Conveyor Belt Speed X 1100 --------800

It should be noted that for structural design, unit weight of coal shall be assumed as 1100 Kgs. / Cu. M. instead of 800 Kgs. / Cu. M. considered for system sizing purpose. Conveyor Gallery structure shall be designed considering both conveyors operating simultaneously.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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PAGE 8 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Conveyor gallery and supporting trestles located between transfer houses / buildings shall be arranged in any one of the following ways. (a) All gallery supporting trestles shall be four legged type only. One end of each gallery span shall be hinged to the supporting trestle and the other end shall be slide type. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements. In between transfer houses / buildings, four legged trestles shall be placed at a maximum interval of 90 metres. The arrangement shall be such so as to ensure that force in the longitudinal direction (i. e. along the conveyor length) of conveyor gallery of length not more than 90 m is transferred to any four legged trestle. In the space between each successive four legged trestles, two legged trestles shall be provided at regular intervals. The end supports resting on the four-legged trestle can have either ends hinged or one hinge and the other on slide type depending on the arrangements. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements.

(b)

End of conveyor gallery which will be supported over transfer house, shall be so detailed that only vertical reaction is transferred from conveyor gallery and no horizontal force in longitudinal direction is transferred from conveyor gallery to transfer house structure and vice - versa. For trestles and trestle foundations for conveyor galleries located adjacent to existing structures, over ground and under ground facilities, location and details of these trestles and foundations shall have to be decided such that there is no interference both underground as well as over ground with existing structures and facilities. Trestle columns / ground conveyor portal column base shall be kept 300 mm higher than the existing ground level. 4.03.00 Transfer Houses The over ground portion of the transfer house shall be framed structure of structural steel work with permanently colour coated profiled steel sheet side cladding and R. C. C. floors 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 shall be provided. In addition to steel windows, panels of suitable size to suit the architectural treatment and made of translucent sheets of polycarbonate material shall also be provided on the side cladding for natural lighting.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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PAGE 9 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Crusher House The crusher house shall be framed structure of structural steel work with permanently colour coated profiled steel sheet side cladding. However, panels of suitable size to suit the architectural treatment and made of translucent sheets of polycarbonate material shall also be provided on the side cladding for natural lighting. The lower portion of side cladding for a height of minimum 0.9m above the finished floor level shall be of one brick thick wall plastered on both faces. Floors and roof shall be of R. C. C. supported on steel beams. Within this building cubicles are to be provided for resting room of operators and these shall be constructed with one brick thick brickwork having both sides plastered and roof slab. Roof shall be provided with roof water proofing treatment as specified elsewhere. Adequate steel doors and windows for natural lighting and ventilation shall be provided. Ring Granulator Type Crushers shall be supported on R. C. C. deck, which in turn will rest on suitable vibration isolation system consisting of springs and dampers. This R. C. C. deck shall be isolated from the floor. However, the vibration isolation system consisting of springs and dampers may rest on main building framework. Detailed specification of vibration isolation system including the unbalanced force (due to ring granulator), frequency and amplitude criteria and other design requirements are appended elsewhere in this specification. Four Roll type crusher also shall be rested on floor with or without vibration isolation system, depending on machine and structural and service requirements.

4.04.00

4.05.00

Control building, M. C. C. Buildings These shall be R. C. C. framed structures with columns, beams, slabs and foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof shall be provided with roof water proofing treatment, as specified elsewhere in the Technical specification. In case of control building suitable permanent interconnection shall be provided at appropriate level with the existing respective buildings. All air - conditioned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system (details specified elsewhere). Adequate aluminium doors and windows shall be provided for natural lighting, ventilation and view.

4.06.00

Pump Houses These shall be of R.C.C. or steel framed structure with columns, beams, slab and foundations etc. cladding shall be of brick work with plastering on both sides. Roof shall be provided with roof water proofing treatment as specified elsewhere. Underground sump and water tanks shall be of R.C.C. Adequate number of doors, Windows and Rolling Shutters shall be provided.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 10 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Galvanized steel ladder / rung ladder shall be provided for access to the roof level of the pump house and water tanks.

4.07.00

Pent House These shall be of R. C. C. framed structures with columns, beams, slabs and foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof shall be provided with roof water proofing treatment as specified elsewhere. Adequate nos. of steel doors and windows shall be provided for natural lighting and ventilation.

4.08.00

Toilets Toilet with potable water line facilities shall be provided in each of the following locations: Crusher House (Ground & Drive Floor) 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 pattern, W.C. pan with high level flushing cistern (C.I.) and all requisite fittings Bowl type Urinal with automatic flushing cistern (C.I.) and all requisite fittings Wash Basin 630 mm x 450 mm with two taps and all requisite items Mirror 600 mm x 450 mm x 5.5 mm thick with bevelled edges (Superior sheet glass) C.P. Brass Towel Rod 600 x 20 mm Liquid Soap Container Washing Tap (CP Brass) Overhead Polyethylene water tank (min. 500 litres capacity) Suitable provision for installation of water coolers. 1 No.

(ii)

2 Nos.

(iii)

2 Nos.

(iv)

2 Nos.

(v) (vi) (vii) (viii)

1 No. 2 Nos. 2 Nos. 1 No.

(ix)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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PAGE 11 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Staircases 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 1000 mm wide)and maximum rise should not be more than 180 mm and minimum tread width 250 mm. Stringers shall be of rolled steel channel (minimum ISMC 250) and tread shall be of steel gratings. Stairs shall be provided with 32 mm dia nominal bore medium duty M. S. pipe hand rail. Handrails (for staircases, around openings, in walkways etc.) shall be of standard weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal bore medium class pipe provided with double rail, top rail about 1.0 metre above platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail post may be provided when specifically called for in drawings approved by Engineering. Handrails around openings should have toe plates. Smooth uniform curves and bends shall be provided at stair returns and also where so ever required. Posts connected to curb plates shall have a neat closure at the bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All necessary fittings including inner dowels at splices, brackets, belts, bends, flanges and chains, where required shall be plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all points of direction changes in the handrail. 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.

4.09.00

4.10.00

Trenches All trenches for cables or any other underground facility as detailed out elsewhere shall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers / chequered plate cover. Cable trenches as well as pre - cast covers shall be provided with edge protection angles and lifting hooks. All embedments / block outs as required and specified elsewhere in these specifications shall be provided. Proper drainage arrangement shall be provided. Trench pre - cast cover weight shall not be more than 65 Kgs. Trench covers near entry or at road crossings shall be designed

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 12 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS for 10 T wheel load at centre. Pre - cast covers shall be designed for central point load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of cables, up to top level and covered with pre - cast R. C. C. covers. For cable trenches outside buildings, top level shall be 200 mm above G. L. Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection all around cut outs / openings in floor slabs, edges of drains supporting grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers, supported edges of pre - cast cover, treads of RCC stairs.

5.00.00 5.01.00

DRAINAGE & WATER SUPPLY WORKS Drainage System:The drainage arrangements shall be so planned so as to ensure quick disposal of drainage water without stagnation and / or overflow. It is envisaged to clean the conveyor galleries, transfer points, crusher building, penthouse etc. with water periodically. Minimum 4 nos. down comers shall be provided in each transfer house / crusher house. In case of conveyor galleries, the down comer shall be provided at every trestle location. For Conveyors 38 A/B, 39 A/B, 21 each down comer shall lead the water / coal slurry to pit (of 2 Cu.M capacity) to allow settling of coal. The water from the pit shall overflow into contractors R.C.C drain, which will lead the discharge finally into owners drain routed alongside the nearby road. For Crusher House, Pent House, JT-1, JT-2, & JT-3 each down comer shall lead the water / coal slurry into the peripheral drains (Brick drains with steel gratings provided around the building) which will lead the water / coal slurry to contractors RCC drain , which will lead the discharge finally into owners drain routed alongside the nearby road. In case of Control rooms and M. C. C. buildings Pump houses, etc, water / coal slurry coming from down comers shall discharge into peripheral drains (Brick drains with steel gratings provided around the building) which will lead the water / coal slurry into contractors R.C.C drain, which will lead the discharge finally into owners drain routed alongside the nearby road. Suitable kick plates/Curb beams shall be provided around the floor openings, stair case landings, in the transfer points, crusher house and other buildings. Contractors scope shall also include construction of necessary culverts under the rail lines / roads as per railway / I. R. C. standards and approval of Railway culverts from concern Railway authorities.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 13 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Internal and external water supply, drainage etc.:The scope for potable water supply includes all distribution systems, tanks, pipes, fittings etc. as required and as described here or elsewhere in these specifications. The scope for service water supply and dust control water supply shall be as described elsewhere in these specifications. For water supply, medium class galvanized mild steel pipes conforming to IS: 1239 shall be used. The scope for drainage of surface water shall include design, layout and construction of drains for and from buildings and drains required for coal stockyard area, drainage up to main coal slurry settling tank including connection with the tank. Drainage system shall be designed for maximum intensity of rainfall as 75 mm/hr and 60 % runoff coefficient. All buildings (including transfer houses and crusher house) shall be provided with open surface brick drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All drains excepting the peripheral drains around the transfer points, crusher house, control / M. C. C. buildings, pumps house etc., shall be of R. C. C. construction. All open drains shall have removable steel grating designed for loads as specified under loading clause. Minimum thickness of grating (Galvanised to 610 gm/m2) shall be 12 mm. However at entry or road crossing points minimum thickness shall be 40 mm. The opening size of grating shall not be more than 90 mm x 35 mm. All drains as well as pre - cast covers shall be provided with edge protection angles and lifting hooks. 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 covers near entry or at road crossings shall be designed for 10 T wheel load at centre. RCC pre - cast covers shall be designed for central point load of 75 Kgs. The scope for foul water from toilets shall include layout and laying of sewers up to the Employers main sewer line for sewerage system together with all fittings and fixtures and inclusive of ancillary works such as connections, manholes and inspection chambers within the building and from the building to the Employers sewer line. For rain water down comer and those to be used for conveying water / coal slurry generated from cleaning of conveyor gallery and buildings floors, Galvanised MS pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded joints shall be used for MCC buildings, pump houses, penthouse, control rooms. Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330 conforming to IS: 3589 with welded joints shall be used for all TPs, Crusher house, and Conveyor galleries. Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall 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.

5.02.00

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IID-01 CIVIL WORKS

PAGE 14 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS All rain water down comers shall be provided with roof drain heads and complete with shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive painting over a coat or primer. For design of building drainage system IS: 1742 shall be followed. For sanitary / sewerage pipes above ground, sand cast iron pipes conforming to IS : 1729 with leak proof lead joints. For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail crossing R.C.C. box culvert to be provided. For sewerage below ground stoneware pipes conforming to IS: 651 with concrete bedding and haunch.

6.00.00

COLOUR COATED AND OTHER SHEETING WORK Permanently colour coated sheet of approved shade and colour using galvanised 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 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 strength of 350 as per AS1397. Steel shall be colour 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 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) 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, 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 preferably be not less than 4.5 cut pieces shall not be used, unless specifically 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.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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PAGE 15 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS For wall cladding insulated / uninsulated and conveyor gallery sides and roof, permanently colour coated sheet of troughed profile shall be used. The nominal depth of trough shall be 30 mm. The polycarbonate sheet to be used for cladding and glazing purpose in conveyor galleries shall have toughed profile to match with the metal cladding profile. Minimum 2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic or equivalent approved make shall be used. The polycarbonate sheet shall be installed along with the metal cladding so as to have a watertight lapping arrangement. Suitable detailing shall be made to cater for the thermal expansion. IS : 14434 to be referred for other details. Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous use under temperature 100oC), impact resistant and ultraviolet resistant sheet shall be provided (as glazing) in transfer houses, pump houses, etc.

7.00.00

ROOF DETAILS Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom. 900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided over roofs of all buildings. Parapet wall shall have suitable coping. External face of parapet wall of the buildings provided with metal cladding shall also be finished with metal cladding of design and colour as per approved architectural drawings. Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet. Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished with 12 mm 1 : 3 cement : sand plaster. Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms, penthouse etc., shall have roof water proofing treatment. Roof water proofing treatment shall be as follows: (1) Application of polymerised mastic over the RCC roof to achieve smooth surface as primer coat. Application of high solid content liquid applied urethane based elastomeric water proofing membrane, over the primer coat, to give uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898). For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This gradient shall be provided by screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1: 4) over the elastomeric water proofing membrane with 25mm thick cement mortar (1:4) topping.

(2)

(3)

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

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CLAUSE NO.

TECHNICAL REQUIREMENTS (4) Wearing course at top, shall consist of 25 mm thick P. C. C. (M-15) cast in panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized chicken wire mesh and sealing of joints using sealing compound / elastomeric water proofing membrane. Pathways for handling of materials and movement of personnel shall be provided with 22 mm thick chequered cement concrete tiles as per IS : 13801 for a width of 1000 mm in place of P. C. C.

8.00.00

FLOORS AND GRADE LEVEL DETAILS The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom Floors of transfer points shall have cross slope of not flatter than 1: 80, towards the floor washing drainage outlets, for efficient drainage. For ground conveyor & crusher house slope shall be 1:100. Chequered plates (used for floors, walkways etc.) shall be minimum 6 mm thick o/p or as indicated on drawings. The chequered plate pattern shall be approved by Employer / Engineer. Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered plates at a designed spacing to stiffen chequered plates suitably. Chequered plates shall be fixed by staggered welding of suitable size. Floors of trenches shall have integral finish to concrete base. Toe guard of size 100 x 6 mm shall be provided at various openings provided in floors e.g. around stair case openings, chute openings and other similar cutouts. For conveyor walkways, angle runner to act as toe guard shall be provided. All along the periphery of R. C. C. floors (where no brick masonry walls are provided) shall be provided with one brick thick 300 mm high brick wall and 700 mm high steel hand rails all around over this brick work. The grade slab shall consists of 230 mm thick rubble soling (63 mm downgraded hard stone aggregate as per IRC specification, watering and compaction to minimum of 90% Standard Proctor density, including filling the interstices of stone aggregates with sand), over well compacted earth, overlaid by 75 mm thick P. C. C. M-7.5 and 100 mm thick R. C. C. of grade M-20 with minimum 8 mm dia bars placed at 200 mm C / C in either direction respectively. There will be minimum 50 mm thick metallic hardener finish over the R. C. C. slab. All buildings (including track hopper and machinery hatches, penthouse, transfer houses and crusher house) and ground conveyors shall be provided with 750 mm wide plinth protection all around. It consists of 50 mm thick P.C.C. M-20 grade with 12 mm maximum size aggregate over 200 mm thick stone soling using 40 mm nominal size rammed, consolidated and grouted with fine sand. An area of 5 m width all round the transfer houses and crusher house shall be paved. This paving will be in addition to plinth protection. The paving construction shall be as per specifications for the grade slab at ground level. However, 50 mm thick metallic hardener finish is not required to be provided in paved area.

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

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PAGE 17 OF 55

CLAUSE NO.

TECHNICAL REQUIREMENTS Plinth level of all buildings shall be kept at least 500 mm above the finished grade / formation level.

9.00.00

BRICKWORK AND ALLIED MASONRY WORKS All brick walls shall be non - load bearing in-filled panel walls. All brickwork shall be designed as per Indian Standards and shall be plastered on both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand mortar. Brick walls shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand plaster on smooth and rough face of the brick work respectively. Bricks to be used in brickwork shall be of minimum Class designation 50. Brickwork cladding for various structures shall be so provided that there is a clear gap of 40 mm between inside face of external brick wall and outside face of column flange. Structural steel wall beams supporting brickwork shall be suitably encased with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam, encasement shall be done with cement sand plaster in specified thickness and proportions over G. I. wire netting of 0.9 mm thickness. Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be provided with drip course in 1 : 4 cement sand mortar. 50 mm thick Damp proof course shall be provided at plinth level for all brick wall. All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided with false ceiling) shall be provided with 6 mm thick plaster.

10.00.00

EARTHING MAT 40 mm Dia MS Rods as earthing mat, placed at a distance of 1.0M away and at depths between 0.60M and 1.00M shall be supplied and laid all around the periphery of buildings, structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS Rods and connecting to the above Earthing mat shall also be supplied and laid in position by the Contractor, as per the approved drawings. Risers shall be laid up to a height of 300 mm above the local Ground level, at each of the columns of the buildings on outside of the buildings, and minimum 2 (Two) numbers for structures and outdoor equipment. The contractor also supply and lay necessary number of 3.0 M deep vertical 40 mm Dia MS Rods Earthing electrodes and connecting them to the Earthing mat, as per the approved drawings and the supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing mat with the Employer's earthing mat separately at two locations.

11.00.00

FENCING Fencing with toe wall and steel gates shall be provided around the transformers. Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G (including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall.

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TECHNICAL REQUIREMENTS The diameter of the steel wire for chain link fence (excluding PVC coating) shall not be less than 12G. Fence posts shall be of pre cast R. C. C. of minimum M20 grade. All corner posts will have two stay posts and every tenth post will have transverse stay post. Suitable R. C. C. foundation for the post and stays shall be provided based on prevailing soil conditions. Gates shall be sturdy with locking provisions. Toe walls of brick masonry shall be provided between fence posts all along the run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend minimum 300 mm below the formation level. Toe wall shall be plastered on both sides and painted with two coats of cement paint of approved colour and shade. Toe wall shall be provided with weep holes at suitable spacing.

12.00.00

LOADING For consideration of loads on structures IS : 875 - Code of practice for structural safety of buildings shall be followed. In addition to the dead load, live load, equipment load (including impact / vibration). Temperature loads etc. various loading conditions arising due to operation and maintenance of equipment shall be considered in the design. The structure and equipment shall also be designed for seismic loads as per the Criteria for Earthquake Resistant Design of Structures and equipment" and the Criteria for Wind Resistant Design of Structures and equipment" specified in the Annexure A and B respectively in Civil Section, whichever is governing. Wind and seismic forces shall not be considered to act simultaneously. The following minimum live loads shall be adopted for the design of various structures. If actual expected load is more than the specified load, then actual load is to be considered. a) Roofs 150 Kgs. / Sq. M. for accessible roofs and 75 Kgs. / Sq. M. for non accessible roofs. In addition to this coal dust load (Dead load) of 150 Kgs. / sq. m. on flat roofs & 75 Kgs. / sq. m. on inclined roofs shall also be considered. b) R. C. C. floors c) Stair and balconies d) Toilet rooms e) Chequered plate floors 500 Kgs. / Sq. M. 500 Kgs. / Sq. M. 200 Kgs. / Sq. M. 400 Kgs. / Sq. M.

f) Walkways (including walkways in 300 Kgs. / Sq. M. conveyor galleries) g) Conveyor galleries In addition to the live loads, loads due to cable trays, fire fighting / service water pipes shall also be considered @
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TECHNICAL REQUIREMENTS 125 Kgs. / m (minimum) on each of the longitudinal girder. Roof-truss members are to be checked for supporting fire fighting pipes/ Service water pipes. Tentative locations and diameter for pipes are shown in Tender Drawing. h) Road Culverts and its allied For class 'AA' loading and checked for structures including R. C. C. pipe class A loading as per IRC standard. crossing & road crossing of trenches. i) Channels / trenches In addition to earth pressure and water pressure, etc. additional earth pressure due to surcharge of 2T / Sq. M. shall also be considered for design. Covers for channels & trenches, shall be designed for a live load of 0.4T Sq. M. and loading as mentioned under clause in trenches, whichever is critical. other In addition to earth pressure with a type surcharge of 2T / Sq. M. (or surcharge due to Railway loading whichever is critical for Railway load bearing 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 ). Earth with surcharge outside and no water / liquid inside

j) Covers for trenches / channels

k) Sumps and underground structures

tanks and basement

ii)

iii) For underground (basement) structures protection against buoyancy during execution and after execution shall be ensured without superimposed loadings with minimum factor of safety of 1.2 against buoyancy. l) Unit weight of coal shall be taken as 1100 Kgs. / cum. for design purposes.
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TECHNICAL REQUIREMENTS If the erection load is higher than the specified live loads on any floor or part thereof, then the erection loads are to be considered for the design. Permissible increase in stresses of materials and bearing pressure of soil due to wind load or seismic load shall be as per relevant I. R. S. and I. S. code.

13.00.00

DESIGN CRITERIA The loads for all railway load bearing structures e. g. track hopper including machinery hatches, wagon tippler, tunnel and under ground transfer houses etc. and the analysis and the design of these structures shall be made strictly in accordance with the provisions of Indian Railway Bridge rules (latest edition), and Indian Railway Codes of practice (latest edition) with all amendments up to the date of opening of bids. However, the axle load for analysis and design shall be considered as 30 MT. Coal heap of 1.2m height shall be considered above hopper top for design of coal tray, hopper and supporting elements of track hopper. The analysis, design and detailed drawing for the structure coming below the railway track shall be got approved by the contractor from the concerned railway authorities before taking up construction. 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 for plain and reinforced concrete for general building construction, IS : 456 (latest). The steel structures shall be designed and fabricated as per code of practice for use of structural steel in general building construction, IS : 800 (latest) and other relevant IS Standards. Minimum size of the angle section to be used as structural members shall be 50 X 50 X 6. Minimum weld size shall be 6 mm. Connections shall be designed for 70 % of shear capacity of the member or the actual shear force, whichever is higher. The building shall conform to local bye - laws, rules and regulations for industrial buildings and also B. I. S. publications, SP 32 and 41. Slotted holes shall not be assumed to act as expansion joint for relieving of stresses and suitable bearings shall be provided at the supports. All gallery supporting trestles shall be so proportioned that the transverse deflection of gallery due to wind / seismic load should not exceed trestle height / 1000 as stipulated in IS: 11592. This deflection condition shall be strictly followed. Peak wind speed method shall be considered for checking the transverse deflection. The crusher and transfer house structures shall be so designed that transverse deflection at places where conveyor galleries meet, should be equal to the respective transverse deflection of conveyor supporting trestles. Stresses for all CHP structures shall be checked for the higher of the forces obtained from gust factor method and the peak wind speed method.

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TECHNICAL REQUIREMENTS The permissible vertical deflection for beams supporting drive machinery shall be restricted to span / 500 and for other beams it shall be within span / 325. Horizontal bracing system shall be provided at floor levels around the openings. Shear force in steel columns shall be transferred to the pedestals / foundations exclusively either through foundation bolts or the shear key arrangement. For design of liquid retaining structures, IS : 3370 (Part - I to IV) (latest) shall be followed. Face of the structure in contact with liquid shall be designed as un cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458, IS : 783 should be followed. For design of all underground structures / foundations, ground water table shall be assumed at the formation level (i. e. the adjoining ground level). Design of Hopper walls shall be done for both Static & Dynamic flow condition using Walkers theory. Design of masonry walls shall be made as per IS : 1905. Civil task drawing indicating various equipment loading and supporting arrangement and floor loads to be submitted along with the design calculation. For metal roofing and side cladding, the spacing of purlins/runners shall be such that the deflection of metal sheet used is limited to span/250 under adverse loading condition. Minimum reinforcement shall be provided at the top face of the footing, even if, no reinforcements are required as per design.

14.00.00

CONCRETE All R. C. C. works to the done under this specification, unless specified otherwise shall be design mix concrete. Minimum grade of concrete for various structures shall be as follows: (a) (b) (c) M35 M25 M20 For Wagon Tippler structure. For underground / sub structural R. C. C. work. For R. C. C. superstructure works including ground floor slabs, trenches & drains.

Minimum 75 mm thick P.C.C M-7.5 shall be provided as mud mat below all foundations. For concreting of underground structures requiring water tightness, plasticizer cum water proofing admixture shall be added to the concrete mix.

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TECHNICAL REQUIREMENTS Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting etc. unless otherwise mentioned.

15.00.00 15.01.00

EXCAVATION DETAILS Excavation in soil Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing or as directed by the Engineer. The bottom of all excavations shall be trimmed to required levels and when excavation is carried below such levels by error, it shall be brought back to the specified level by filling with concrete of nominal mix 1:3:6 (cement: coarse sand: 40 mm down aggregates ), as directed by the Engineer. The Contractor shall ascertain for himself the nature of materials to be excavated and the difficulties, if any, likely to be encountered in executing this work. Cofferdams, sheet piling, shoring, bracing to maintain suitable slopes, draining etc. shall be provided and installed by the contractor, to the satisfaction of the Engineer. Surplus excavated materials shall be disposed off by the contractor at locations up to a lead of 5 kms from the plant boundary wall as directed by the engineer. The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, Backfilling is completed. The Contractor shall remove all slush/muck from the excavated areas to keep the work area dry. The Contractor, if required, shall employ sludge pumps, for this purpose. For other details, excavation clauses as given in Sub-Section III-D-02 are to be referred.

15.02.00

Excavation in rock For the work of excavation in rock, Contractor shall engage specialised agency having experience of excavation in rock involving wedging and blasting. The agency shall be subject to approval of Engineer and the Contractor shall furnish details of relevant experience in support while seeking approval for the agency. Blasting shall be resorted to only with the written permission of the Engineer. All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to the acquisition, transport, storage, handling and use of explosives etc. shall be strictly followed. The contractor shall obtain Licenses from Competent Authorities for undertaking blasting work as well as for procuring, transporting to site and storing the explosives as per Explosives Act. The Contractor shall be responsible for the safe transport, use, custody and proper accounting of the explosive materials. Surplus excavated materials shall be disposed off by the contractor at locations up to a lead of 5 kms from the plant boundary wall as directed by the engineer.

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TECHNICAL REQUIREMENTS The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, backfilling is completed.

15.03.00

De-watering of Deep Excavations For deep underground structures like track hopper, machinery hatches, tunnels and underground transfer houses, requiring open excavation with extensive de watering, completely dry working conditions during excavation, shuttering, placement of reinforcement, concreting, water proofing of structures, backfilling and any other operation shall be maintained by suitable de - watering method of suitable capacity.

15.04.00

Backfilling, Disposal and Stacking of materials Backfilled earth shall be compacted to minimum 90 % of the standard proctor density at OMC. Sand filling shall be compacted to minimum 80 % of the relative density. Also refer Sub-section III D-02 for more details. However, the backfill under the rail lines and roads shall be compacted to minimum 95 % of the standard proctor density at OMC unless otherwise stated by rail Authorities. The contractor is required to excavate upto any depth as shown on the drawings or as directed by the Engineer. Lifting of excavated materials shall be done either by manual or mechanical or both means if called for by the Engineer. The disposal / stacking areas for excavated materials shall be indicated by the Engineer. The carriage of excavated materials shall be done by the methods mentioned below: The excavated materials shall be carried beyond the initial lead of 50 m but upto 500 m by manual / animal labour or by mechanical means. If directed by the Engineer this material shall be used directly for filling purposes. For leads exceeding 500 m the Contractor shall transport the excavated materials by mechanical means only and as directed by the Engineer. The Contractor may be allowed to carry materials through Kuccha roads. Providing and maintaining of the Kuccha roads shall be the responsibility of the Contractor. The transported material shall be neatly stacked as directed by the Engineer. Some excavated materials required for filling purposes, may have to be carried upto a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials carried beyond 500 m shall normally be for disposal purpose only. Double handling of materials shall be avoided as far as possible. However, depending on site condition excavated materials carried beyond a lead of 500 m may also be required to be brought back for filling purpose.

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TECHNICAL REQUIREMENTS Materials to be used for filling purpose shall be stone, sand or other inorganic materials and they shall be clean and free from shingle, salts, organic matter, large roots and excessive amount of sod, lumps, concrete or any other foreign substances which could harm or impair the strength of the substances in any manner. All clods shall be suitably broken to small pieces. When the materials are mostly rock boulders, these shall be broken into pieces not larger then 150 mm size. Sand used for filling shall be clean, medium grained and free from impurities. Fines less than 75 microns shall not be more than 20%. In any case, the materials to be used for filling purposes shall have the prior written approval of the Engineer. In case the materials have to be brought from pits / quarries, then it shall be the Contractors responsibility for identification of such quarry areas, obtaining approval from their use from concerned authorities, excavation / quarrying loading and carriage of such material, unloading and filling at specified locations. The Contractor shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow areas.

16.00.00

GALVANISING All burrs and irregular edges of the structural steel members to be galvanised shall be ground smooth before galvanising. Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest edition ). The weight of the zinc coating shall be at least 610 Gms. / m2 unless noted otherwise.

17.00.00

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 1.5 m c / c before concreting operation. Adequate precaution shall be taken to keep the nozzles plugged at both ends to prevent them from getting closed by concrete. For fixing of any nozzle in set concrete suitable size hole shall be drilled, 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 be injected through the net - work of nozzles with low pressure grout pumps at a pressure of about 2.0 Kgs. / cm2. Cement slurry shall be prepared by mixing cement with 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 (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

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TECHNICAL REQUIREMENTS very low pressure and increased gradually to a required pressure. The grouting shall continue, 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.

18.00.00 18.01.00

POLYMER MODIFIED CEMENTITIOUS COATING 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.

18.02.00

Mixing The liquid polymer shall be stirred well and cement based powder shall then be added 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.

18.03.00

Properties of Coating It must adhere to wet surface. It should develop adequate bond strength, with the concrete surface, not less than 2 N / Sq. mm. Co - efficient of permeability shall be about 5x10-10 Cm / Sec. Water absorption after continuous soaking shall not be more than 1 %. The materials shall be permeable under water vapour. The material shall be resistant to acids and alkalies 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.

18.04.00

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 exterior underground part, application (b) pertaining to Brush topping Mix shall be followed.

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TECHNICAL REQUIREMENTS (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. / m2 in the 2 coats. A lap of 75 mm shall be provided at the joints. The coating 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 first applied on the surface as first coat. After the coating has dried up, a coat of Brush Topping Mix shall be applied over it with a push broom or any other similar brush. It shall be left in broom finished condition. The nominal thickness shall be 1.5 mm and minimum thickness shall be 1.0 mm. A lap of 75 mm shall be provided at the joints. It shall be ensured that no pinhole exists and rebrushing shall be done to cover the pinholes, if any. The Coating shall be air dried for 4 to 6 hours and thereafter cured for 7 days after the application of last coat. Rate of application of coating shall be established to achieve the required thickness.

19.00.00

ARCHITECTURAL FEATURES All architectural features of buildings like control rooms, crusher houses, M. C. C. rooms, transfer houses and conveyor galleries etc. shall be detailed by contractors qualified architect. Necessary projections, fins etc. in addition to the minimum specified elsewhere in this specification shall be provided as required. The Contractor for Employers approval shall submit detailed architectural drawings along with colour schemes. Nothing extra shall be payable for any changes required while getting the drawings / schemes approved and for executing the same. In case structural column base plates are proposed below the floor level, the same shall be encased with adequate cover up to the finished floor level with minimum M 20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin reinforcement of the encasing.

19.01.00

Glazing Window glazing for various locations shall be as below: (i) In transfer houses, crusher house and pump houses etc: Polycarbonate sheet (Details described elsewhere).

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TECHNICAL REQUIREMENTS (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 insulation at partition of A / C and non A / C areas. (b) In toilets: Ground glass of minimum thickness 4 mm. (c) In other areas: Toughened glass of minimum thickne