Académique Documents
Professionnel Documents
Culture Documents
for
Planning, Design, Engineering, Construction, Fabrication,
Supply, Erection, Trial Run and Commissioning of 2x 40/50
MVA, 132/33 kV substation which includes all the
electrical outdoor and indoor equipment, lighting system,
earthing system, lightning protection system, signalling and
control system, DG set, fire fighting system, structural and
civil works, drinking water supply system etc. on Turnkey
Basis at Kusmunda OCP,SECL
(KUSMUNDA AREA)
SOUTH EASTERN COALFIELDS LIMITED
(A MINI RATNA COMPANY)
VOLUME II
(TECHNICAL )
INDEX
List of Drawings
2.1.0.0 INTRODUCTION
2.1.1.0 PREAMBLE
2.1.1.5 The scope of work shall be read along with Basic data, Plant description and
Specifications of the equipment/items, civil and structural works etc. which are
elaborated in subsequent clauses/chapters.
2.1.2.2 The project is at a distance of 10 km from Gevra Road Railway station and
15 km from Korba Railway station. These stations are on the branch line of
Champa and Gevra Road Railway Station. The Gevra Road Railway Station
is about 100 km from Bilaspur and 708 km from Howrah by rail.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 1
Introduction NIT for 132/33 kV Substation at Kusmunda OCP
2.1.2.3 The project is well connected by all weather metal Road. It is about 105 km
from Bilaspur, the head quarters of SECL and about 15 km from Korba.
2.1.3.0 PHYSIOGRAPHY
2.1.3.1 The general topography of the project is gently undulating with elevations
ranging from 280 m to 300 m above mean sea level. The drainage is mainly
by Hasdeo River which marks the south western boundary of the block .
2.1.4.1 The climate of the area is dry to moist tropical with well defined summer from
April to June, rainy season from July to September and winter season from
October to March.
2.1.4.2 The average annual rainfall is about 1456 mm. The highest rainfall recorded
within a period of 24 hours over the last 20 years is 278 mm in September
1991
2.1.4.3 The relative humidity varies from 70 to 100% during monsoon and 17 to 78%
during summer.
2.1.4.5 The wind direction is generally westerly to south westerly with wind velocity
varying from 0.57 to 13.38 km/h.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 2
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.2.1 In the out door yard of the Substation one number of 132 kV
sectionalised over head strung bus will be provided. Two numbers of
over head lines will feed power to the sectionalised over head strung
bus through pole mounted motorised 132 kV Isolators and 132 kV SF6
circuit breakers. The incoming Isolators will be provided with earthing
switch and station class Lightning Arrestor. Power will be supplied from
the bus to the primary side of the 132 /33 kV Transformer through
Isolator, Current Transformer (CT) and SF6 Circuit Breaker. Tapping
will be provided on each side of the132 kV side sectionalised bus for
feeding power to 132kV/3 / 33kV/3 Potential Transformer (PT)
through Isolator. One 132 kV station class Lightning Arrestor will be
provided before each Transformer. The 132 kV current Transformer,
Lightning arrestor, SF6 Circuit Breaker, 132kV/33kV Transformer will
be kept in one line as shown in the GA Drawing RV/ELC/200279. The
132 kV strung bus shall have two nos. 132 kV isolators, one number
SF6 circuit breaker and one number CT for sectionalizing.
2.2.2.2 Two overhead sectionalised strung buses (Main and Auxiliary) each of
33 kV and circuit breaker of 33kV will be provided on the 33kV side of
the 132/33kVtransformer (40/50 MVA rating each). Required number of
Isolators, Vacuum Circuit breaker and CT will be provided for
sectionalising the buses and to avoid Parallel operation of transformers
as shown in the Drawing RV/ELC/200279. From the secondary side of
the 132kV/ 33 kV Transformers, power will be fed to the respective
sections of the 33kV over head sectionalised strung Main bus through
out door type 33kV Vacuum Circuit Breakers, Current Transformer,
Lightning arrestor, Isolator etc. The Main bus will be coupled with 33 kV
auxiliary bus through Isolators and Vacuum circuit breaker for
energising auxiliary bus. Normally power will be supplied to the out
going feeders from the main bus through 33 kV, Vacuum Circuit
Breakers, CTS, Isolators (with earth blade) etc. The out going feeders
are also connected with auxiliary bus through isolators. These isolators
will normally be in OFF position. If VCB of a particular feeder is out of
order or is required to be shut off for maintenance purpose, then the
Isolator between this feeder and auxiliary bus will be made ON to avail
power from auxiliary bus for which auxiliary bus will be energized.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 3
System Description NIT for 132/33 kV substation at Kusmunda OCP
From both the sections (I &II) of the 33kV sectionalised bus, power will
also be tapped through Isolators and HG fuses for feeding power to
Potential Transformers (PTs) and 200 kVA, 33kV/0.44-0.23 kV ( L-L)
Transformers. The 200 kVA Transformers will meet the requirement of
both lighting loads (at 230 V, L-L) and other industrial loads (at 415V)
of the substation. The Potential Transformers will be required to meet
the needs of measurements and instrumentation.
2.2.4.1 Motorised cranking type OFF load isolator shall be provided on the132
kV side and manually operated cranking type OFF-Load Isolators shall
be provided in 33 kV side. The location of isolators is shown in the GA
drawing RV/ELE/200279
2.2.4.2 All the Isolators will be triple pole, double break, centre post rotating,
out door, gang operated type. Suitable inter locking arrangement shall
be provided between the respective Isolators and Circuit Breakers so
that required operational safety can be achieved.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 4
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.6.1 Out door type Current Transformers (CT) of required quantity will be
provided in the switch yard of 132 kV and 33kV system for protection
and metering. The CTs will be provided for restricted earth fault
protection, over current and earth fault protection, transformer
differential protection, bus bar protection, distance protection and for
metering. The accuracy class, burden, CT ratio, accuracy limit factor,
Knee point voltage etc. shall be duly selected based on the system
requirement. The CTs shall conform to IS2705 and IS4201.
2.2.7.1 Required number of SF6 and Vacuum Circuit Breaker as shown in the
single line diagram (RV/ELE/200278) shall be provided in the switch
yard of 132 and 33 kV side for protections.
2.2.7.2 All the Circuit Breakers on 132 kV and 33 kV sides will be of out door
type with indoor control and relay panel.
2.2.7.3 132kV and 33kV Circuit Breakers shall be single pole. The
simultaneous operation of all three poles for close, open and trip shall
be required and ensured through required relays.
2.2.7.4 All the Circuit Breakers will be operated remotely from control room,
however facility for local electrical operation will also be provided.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 5
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.8.0 Control and Relay panel for 132 kV SF6 CBs and 33kV VCBs,
Transformers etc.
2.2.8.1 The out door Circuit Breakers both on 132 kV and 33 kV side will be
controlled remotely from the control panels located in the control room
of the sub station. The control panels will meet the requirements of
control, protection, metering, signaling and annunciation needs of
Circuit Breakers and Transformers. All the relay panels for various
protections on 132 kV and 33 kV side will also be located in the
respective control panels. Various relays for different protection
schemes will be judiciously selected so that their reliability,
effectiveness and quality are of highest order and are suitable for
continuous satisfactory performance over the years. Relays of latest
and improved design and proven quality and reliability will be preferred.
Arrangement for remote tripping by protective relays will be provided.
Automatic indication of operating switches will also be provided.
High speed differential bus bar protection along with local breaker back
up protections under provision of regulation of CEA,2010 is to be
provided.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 6
System Description NIT for 132/33 kV substation at Kusmunda OCP
ii) The 132k V and 33kV strung bus will be protected with high speed
differential bus bar protection scheme along with local breaker back
up protections.
iii) The outgoing 33kV transmission line feeder will be protected for
O/L, E/F and distance protection.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 7
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.12.3 All the meters will be of preferred standard size and of required
accuracy class.
2.2.12.4 Fault annunciation with visual and audible alarm will be provided for
different types of tripping of Circuit Breakers, auxiliary power supply
(AC &DC), air pressure, SF6 gas pressure fall, winding and oil
temperature rise etc. Facility for acceptance of audible alarm will also
be provided.
2.2.12.5 Lamp indictors and semaphore indications with mimic diagrams will
also be provided for various Circuit breakers and Isolators.
2.2.12.6 Lamp indications (Green, Red, Yellow) for power supply (AC/DC) and
other equipment will also be provided.
2.2.12.7 Condition Monitoring & Self Diagnostic Facilities as required will also
be provided.
2.2.12.8 Any other meters and indications other than the above mentioned, if
necessary, for safety and effective operation of the substation will also
be provided.
2.2.13.2 Two nos. 3 Ph-N, 415 V sectionalised Power Distribution Boards will be
installed in the AC/DC room of the substation and this will receive
power from the secondary side of the Station Transformers. Each
power distribution board will consist of two numbers of 400 A , MCCB
acting as an incomer controller, one number MCCB as sectionaliser of
the bus, required number of out going panels with 3 pole MCCB s and
3 and 2 poles MCB s. This switch board will be of industrial type, dust
and vermin proof. From the switch board power will be supplied to the
following:
i) On load tap changer
ii) Cooler control cubicle of transformers
iii) Float cum charging unit
iv) Circuit Breakers
v) On line oil monitoring unit
vi) Transformer oil filtration machine
vii) Other industrial loads
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 8
System Description NIT for 132/33 kV substation at Kusmunda OCP
A separate 3 ph- N , 415 V switch board with change over switch shall
be provided at the pump house.
2.2.13.3 The incomer MCCBs will receive power from the secondary of the
Station Transformers through PVCSWA, 1100 V grade, stranded,
copper conductor cable of suitable size.
2.2.14.1 One set of sealed maintenance free type lead acid batteries along with
two numbers (one working and one standby) float and boost charger
will be provided for supplying power to the following:
2.2.14.2 The batteries will be installed in the wooden racks located in the battery
room of the substation building. The battery will be of minimum 200 AH
capacity. The room will be properly ventilated by exhaust fan. The
batteries will receive power from the float charger.
2.2.14.3 The DC power will be supplied normally through the rectifier cum float
charger and in case of AC power supply is OFF, DC supply will be
affected through the battery. The rectifier / charger will receive from the
3 Ph-N, 415 V Power Distribution Board. Two nos DC Power
Distribution Board ( 110 V) with required MCCBs/MCBs shall be
installed at control room.
2.2.15.1 Main lighting distribution boards 230 V ( L-L) with suitable number of
panels will be provided in the AC/DC room of the substation.
2.2.15.2 The out door substation yard will be illuminated with the help of
luminaries fitted with 400W metal halide lamps on 15m lighting masts
to achieve illumination level as per IS 3646 part-II. Minimum eight
numbers of lighting mast each of at least 15 m height with six numbers
luminaries with 400 W metal halide lamps will be provided for
illuminating the substation out door yard. Twelve numbers of 11 m
height steel tubular poles with 250 W HPSV lamps will be provided
along the road for illumination purpose. Luminaries with 250 W HPSV
lamps will be mounted on the substation building with brackets for
illuminating the area around substation building to achieve the required
illumination level. All the light fittings will receive power from the 230 V
(L-L) lighting distribution boards through 2 core PVC insulated copper
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 9
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.15.4 The indoor substation building will be illuminated with the help of
required number of energy efficient decorative recessed lamps light
fittings to achieve an illumination level of 200 lux (as per IS 3636 part
II). Corridors, toilets, testing rooms etc will be illuminated by suitably
rated compact fluorescent lamps. All the lamps will be placed suitably
to achieve uniform level of illumination. These lamps will also receive
power from the lighting distribution board. DC light fixtures with 40 W
GLS lamps shall also be fitted
2.2.15.5 One number inverter-cum- battery charger along with battery will be
installed in the substation building for emergency lighting in the
substation building in case of failure of power supply.
2.2.15.6 Supply and installation of one no. 63 kVA, 3 ph, 415 V, 50 Hz diesel
generator set (silent type) in the generator shed along with cabling and
change over switch as per requirement.
2.2.15.7 Required number of 1200mm sweep ceiling fans with double ball
bearings and electronic regulators shall be provided in control room,
battery room, testing room, PLCC room, Engineer in charges room,
Engineers room and other rooms. Exhaust fans of 375 mm sweep will
be provided in toilets, battery room, store, DG room, transformer oil
filteration room, oil storage room. Required number of 2 ton capacity
split type air conditioners with 5 star rating including servo stabilizer
shall be provided in the control room, Engineer in charges room.
These will get power from the power distribution board through 2 cores,
PVC insulated copper conductor cables. Required number of switches,
ceiling roses, sockets etc will be provided. For control of air
conditioners, MCBs with industrial type plug and sockets shall be
provided.
2.2.16.1 All the LT power cables( 3 / 4 core, 1.1 kV grade) will be PVCSWA of
suitable size not less than 10 sq mm stranded copper conductors cable
as per requirement.
2.2.16.2 All internal wiring for illumination, ceiling fans, exhaust fans, misc.
items will be done by 1.5 sq mm - 6 sq mm PVC insulated cables of
1100/660V grade with copper conductor cable.
2.2.16.3 All out door illumination circuits will be of PVCSWA, 1100 V grade, 2
cores of required size cables with stranded copper conductors.
2.2.16.4 Internal wiring for air conditioners, power sockets will be carried out by
insulated 660 V grade, of suitable size copper wires/cables.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 10
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.16.5 All internal control wiring of control cubicle , Circuit breakers , Isolators,
CTs etc will be carried out by PVC insulated 660 V grade , 2.5 sq mm
copper wires of suitable no. of cores.
2.2.16.6 All out door control cables will be PVCSWA, 660 V grade, 2.5 sq mm
(min), multi core copper conductors. However in case higher size
cables are required as per the design, the same is to be provided.
2.2.16.7 Cables used with CTs and PTs will be PVCSWA, 2.5 sq mm(min)
multi core copper conductors.
2.2.17.1 132 kV bus will be single sectionlised (with two nos. isolators, one no.
SF6 Circuit Breaker and one no. CT) overhead strung bus with single
ACSR Zebra conductor. The 33 kV bus will be two (Main & Auxiliary)
overhead strung bus. The main bus will be by twin ACSR Zebra
conductor and auxiliary bus will be by single ACSR Zebra conductor.
2.2.18.1 The touch and step potential at substation shall be maintained within
acceptable limit as per relevant IS/ IEEE standards. Earthing of the
complete 132kV/33kV substation will be done strictly in accordance
with the latest revision IS 3043 and Central Electricity Authority
Regulation-2010, IEEE standards & Electricity Act-2003(current). The
specific requirements of earthing in respect of some equipment in the
substation as indicated in IS 3043 are reproduced below for ready
reference:
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 11
System Description NIT for 132/33 kV substation at Kusmunda OCP
Clause 17.8.4The earth connection should not pass through iron pipes
as it would the impedance of the connection.
2.2.18.2 Out door switch yard will have mat Earthing system. While designing
mat grid system, due care will be taken to keep touch potential, step
potential and mat potential within allowable limits as per statutory
requirements. The mat Earthing system will consist of earth grid made
of suitable size galvanised steel strips/flats buried at a depth of
approximately 700 mm below the ground. The size of the grid will be as
per requirements. Sufficient number of earth pits shall be provided in
the substation out door yard and will be connected to earth grid suitably
to keep the earth resistance below 1 ohm or to the specified level
required for EHV substation which ever is low. The earth pits shall be
constructed as per Indian Standard (IS-3043). Two separate earth pits
for each Transformer will be constructed very close to them to which
the neutrals of the Transformers will be connected. Similarly , for each
lightning arrester( LA) set, two numbers of earth pits will be constructed
very close to the LAs to which the LA shall be connected. All other
earth pits shall be distributed suitably over the earth mat. The metal
bodies of the out door equipment shall be connected to the earth mat.
2.2.18.3 Required number of earth pits will be provided along the fencing and
will be inter connected with the help of suitable size galvanised steel
strips / flats buried below the ground at a depth of 700 mm. The fencing
will be connected to this earth grid
2.2.18.4 Required number of earth pits will be provided around the substation
building and will be inter connected with the help of suitable size
galvanised steel strips / flats buried below the ground at a depth of 700
mm. The control cubicles and other equipment will be connected to this
earth grid.
2.2.18.6 Suitable arrangement for watering the earth pits shall also be provided.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 12
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.19.1 Metal Oxide Lightning arrester of station class shall be provided on the
structures of 132kV incoming lines, primary side of the 132/33 kV
Transformers and 33kV outgoing feeders for protection against
traveling waves due to lightning. The 132kV lightning arresters `shall
be provided with surge monitor/ counter.
2.2.19.2 All the 132kV and 33kV structures will be extended by 2m high over the
conductors. At the top of these structures, horizontal shield wires will
be drawn for protection against direct lightning strokes. The shield
wires will be connected to earth by separate earth pits. In addition three
15m high lightning masts is to be erected in such a way that the entire
substation area is protected against lightning. Separate earth pit will be
provided for each lightning mast.
2.2.20.1 Suitable fire fighting system (consisting of hydrant points, electric and
diesel pumps, portable fire extinguishers, sand buckets etc) to quench
electric fires in the out door switch yard, diesel gen. shed, transformer
oil filter/purification shed, oil storage shed, pump room and the
substation building will be provided as per the IER rules. Fire/ smoke
detectors and alarm system will be provided to warn the people
working at the substation. Each control panel (132kV &33kV) shall be
provided with individual fire extinguisher with sensor inside the panel.
The Tariff advisory committee and National Building codes will also be
considered for designing the fire fighting system. Along with these,
CO2 fire extinguisher and chemical powder type ( trolley mounted) are
to be provided.
2.2.20.2 Individual Nitrogen injection system for fire fighting shall be provided
with both the Power transformers (40/50 MVA,132/33 kV).
2.2.21.1 The following will be provided inside the substation for safety and
education on safety:
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System Description NIT for 132/33 kV substation at Kusmunda OCP
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 14
System Description NIT for 132/33 kV substation at Kusmunda OCP
structures
7) IS: 6610 : Specification of heavy washers for steel
structures
13) IS: 731 : Porcelain insulators for overhead power lines with
A nominal voltage greater than 1000 V
14) IS: 486 : Insulator fittings for overhead power lines with a
nominal voltage greater than 1000V.
15) IS: 808 : Rolled steel, beams, channel and angle section.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 15
System Description NIT for 132/33 kV substation at Kusmunda OCP
29) IS: 3116 : Specification for sealing compound for lead acid
batteries.
34) IS: 13947 : Specification for air break switches and fuse
combination units
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System Description NIT for 132/33 kV substation at Kusmunda OCP
52) IS: 2997 : Air circulator type electric fans and regulators
55) IS: 3427 : Metal enclosed switch gear and control gear
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 17
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.23.1 The Civil and structural works covered under this document will
consists of substation building, security room, underground water
storage reservoir, Room for D.G set, transformer oil filteration machine
and oil storage , Galvanized steel structures (Gantries, Towers,
Stools), equipment foundations, rail track for transformer and
transformer foundation, cable trenches, bore well with submersible
pump, sump with pump house, soak pit, septic tank, drainage system,
path ways, boundary wall with gates, drains. car parking shed, watch
tower chain link fencing with gates, anti grass treatment, spreading of
crushed stone in the outdoor yard, drinking and industrial water supply
etc. The design of steel and RCC structures will be as per standard
code of practices for industrial structural/buildings in the absence of
which international standards can be used. Along with this soil
investigation and surface dressing shall also be covered.
During the design of structures, the effect of dead loads, live loads,
dynamic loads, effect of blasting, seismic load etc. wherever applicable
shall be considered. The effect of blasting (maximum charge per delay
of 20,000 kg at a distance of app. 1000 m) will be considered. The
topography factor for design calculations will be considered and shall
not be less than 1.05.
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System Description NIT for 132/33 kV substation at Kusmunda OCP
vii)Tool & Store room Tool room will have locker facilities for
storage of tools.
The floor of stores, transformer oil filtration machine unit, DG room, oil
storage room shall be of I.P.S flooring followed by150 mm thick RCC of
M-20 grade over the base course. The floor finish of Battery room will
be anti acidic. The Engineers room, AC/DC room, testing room will be
glazed tiled. Engineer In charges room shall be glazed tiled. Other
floorings will be I.P.S flooring over suitable base course.
The battery room and toilets will be provided with 375 mm sweep
exhaust fans. Required number of light fittings, fans, sockets, ceiling
roses etc. will be provided. The toilet will be provided with required
sanitary fittings, wash basin etc. Dado in toilet up to height of 1.5 m
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 19
System Description NIT for 132/33 kV substation at Kusmunda OCP
The pump house will be of brick masonry construction with RCC roof.
The plastered internal surface will be finished with plastic emulsion
paint of approved shade, while outer surface shall be plastered and
finished with water proofing cement based paint. The plinth area of the
pump house will be such that a clearance of 1.5 m (min.) on all sides
after installation of pumps (both electric and diesel) will be available.
The floor of the pump house will be IPS over suitable base course
preferably RCC. Required steel windows with square bars and glass
panels, steel door frames of suitable width and 2 m height with flush
door shutters will be provided. The door will be provided with proper
locking arrangement. Required light points, ceiling roses, sockets,
switches etc. will have to be provided.
The ground area in the outdoor yard of the substation switch yard
portion will have to be leveled, suitably conditioned with anti grass
treatment before providing crushed stone. The crushed stones will be
of 25 mm x 25 mm size and will be spread uniformly to reduce shock
hazard. The thickness of crushed stone will be as per design
consideration and approval of DGMS.
2.2.23.5 Units for Diesel generator, transformer oil filtration and oil
storage:
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 20
System Description NIT for 132/33 kV substation at Kusmunda OCP
Two nos. of PVC tanks each of 2000 lit capacity will be provided on the
roof of the substation building. One tank will be for supplying drinking
water and the other for supplying water for industrial use. Arrangement
will be provided for connecting the inlet water pipe from water supply
system. Out let pipes from the water tank for industrial use will be laid
up to various earth pits in the outdoor yard of the substation and to
toilets. Required valves, taps etc shall be provided. Drinking water
tank will be connected to water cooler etc.
All the power /lighting cables, control cables will be laid on separate
cable hangers in the cable trenches provided inside the sub station
building and out door yard as shown in Drg. No. RV/ELC/200279. The
cable trenches will be of desired size. The floor of the cable trench will
be provided with a gradient for easy flow of water to a place out side
the substation yard. The trenches provided in the out door yard will be
covered by means of pre-cast RCC covers supported on steel frame
which can be lifted easily. The indoor cable trenches will be covered by
means of aluminum cover of at least 3mm thick and properly stiffened
to avoid bending.
2.2.23.9 Development:-
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System Description NIT for 132/33 kV substation at Kusmunda OCP
Rail track with 45 kg/m rails or of required size will be provided on the
transformer foundations and in front of the transformer so that the
transformer can be taken out for under taking repair in case of
requirement. Diamond crossing is to be provided for easy
transportation of power transformers.
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
2.3.1.0 General
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
iv) Single line diagram showing the size and length of cables for
feeding power to various equipment
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
The civil and structural works are related mainly to following (but
not limited to)
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
vi) Boundary wall with concertina coil on top, Chain link fencing
between the substation and outdoor yard, required gates,
Security rooms, watch tower etc.
Note: - All works are to be executed in accordance to BIS provisions & CPWD
specifications
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
ix) Discharge rods, 3 m long along with the hook, cable etc. 2set
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Scope of work NIT of 132/33 kV substation at Kusmunda OCP
NIT 688 dtd 17.09.14 Job No.502255 (VOL II) Page no- 36
Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.1.1 General:
i) Twelve nos. 132 kV and sixty six nos. 33 kV isolators have been
proposed in the substation at various points where isolators are
intended for control as well as maintenance. These have been
indicated in drawing number R5/ELC/200278 ( single line diagram).
ii) The isolators which are required to have earthing switches will also
be combined in one unit. Interlock shall be provided between the
isolator and the earthing switch to ensure proper operation and safety.
x) Operating mechanism :
xix) IS to be followed
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xxi) All the type test and routine test certificate as recommended in
relevant IS shall be submitted by the Tenderers along with the
offer.
The materials for moving blades and contacts of main switch and
earthing blades and contacts of earthing switch shall be the same.
Cross sectional area of earthing blades and contacts shall not be less
than 50% of cross sectional area of main blade and contacts.
2.4.1.4. Insulators
i) The insulators shall be with solid core insulators only. The insulators
shall be provided with galvanised steel base design for mounting on
the support. The mounting arrangement shall be rigid and self
supporting and without any cross bracing between phases. The
insulators shall be made of homogeneous and vitreous porcelain of
high mechanical and dielectric strength. The glazing of porcelain shall
be of uniform brown or dark brown with a smooth surface to be
arranged to shade away rain water. The porcelain shall be free from
lamination and other flaws or imperfections that might affect the
mechanical or dielectric quality.
ii) A cap shall be provided on top of the insulator and shall be of high
grade cast / malleable steel casting or aluminum alloy. It shall be
machine faced and hot dip galvanised.
iii) The operating mechanism shall provide quick, simple and effective
operation. The design shall be such that one person shall be able to
operate the isolator without undue effort. The earth switch shall close
or open by rotation of lever through 90 degrees. The operating
mechanism shall be suitable to hold the main switch or earth switch in
closed or opened position and shall not change due to gravity, wind,
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.1.6 Gear
2.4.1.10 Interlocking
The main switch and main switch with earth switch are required to be
interlocked with associated switch gear and protection schemes
through auxiliary contacts. Mechanical interlocking shall be provided
between main switch and earth switch. Electrical interlocking shall be
suitable for 110V DC supply. It shall be possible to lock isolator when in
de-energised condition. It shall also be possible to engage the crank for
operation by energising the device through a push button, only when all
interlocking contacts are through.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.1.11 Accessories
iii) Name Plate: Each isolator shall be provided with a name plate
which is weather proof and corrosion proof. Name plate shall be
provided for the isolator and for operating mechanism with the following
data:
2.4.1.12 Signaling
i) Signaling of the close position shall not take place unless the
movable contact has set in position in which the rated normal current,
the short time withstand current and the peak withstand current can be
carried safely.
ii) Signaling of open position shall not take place unless the movable
contact has reached the position such that the clearance between the
contacts is at least 80% of the isolating distance.
2.4.1.13 Tests
i) Type Test
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.1.14 Inspection
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.2.1 The parameters of the lightning arrester /Surge Arrestor are as given
below:
132 kV 33kV
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xix) IS to be followed:
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xxi) The following test certificates shall be submitted by the tenderer along
with the supplies
g) High and low current pressure relief test for 120 kV and 30 kV LA
2.4.2.2 Requirements
ii) The surge arrester shall be fitted with pressure relief devices and diverting
ports and shall be tested as per the IS provisions for minimum
prospective symmetrical fault current of 31.5 kA and 25 kA r.m.s. for 132
kV and 33 kV lightning arresters respectively.
iv) Each individual unit of surge arrester shall be hermitically sealed and fully
protected against ingress of moisture. The hermetic seal shall be
effective for the entire life time of the arrester and under specified service
conditions.
vi) The corresponding units of arresters of the same rating shall be inter
changeable without adversely affecting the performance.
vii) The surge arrester shall be suitable for pedestal type of mounting
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
viii) The 132kV lightning arrester shall be provided with surge monitor/
counter
iii) The grounding terminals shall be suitable for connection to earth mat/
earth electrode.
2.4.2.4 Tests
i) All the type tests as per IS shall be carried out by the Tenderer at
manufacturers works at the cost of Tenderer. Employer may like to
depute his representative for the tests. If already type tested, certified
copies of type tests shall be submitted by the Tenderer along with the
supplies.
ii) The certified pollution test shall be carried out as per IS provisions.
iii) All routing and acceptance tests as stipulated in the IS shall be carried
out by the Tenderer at manufacturers works in presence of Employers
representative at the cost of Tenderer.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.3.1 General
132kV 33 kV
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xxi) IS to be followed:
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.3.5 Standards
The metal tanks shall be coated with at least two coats of Zinc rich
epoxy painting. All the ferrous hardware, exposed to atmosphere, shall
be hot dip galvanised .All other fixing nuts, bolts, washers shall be
made out of Stainless Steel
Insulating oil required for first filling of the instrument transformers shall
be covered in Contractors scope of supply. The oil shall meet the
requirements of latest edition of IS 335.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) Nuts and bolts or screws used for fixation of the interfacing porcelain
bushings for taking out terminals shall be provided on flanges
cemented to the bushings and not on the porcelain.
iii) For joints with gaskets wherever used Nitrite Butyl rubber gaskets
shall be used. The gasket shall be fitted in properly machined groove
with adequate space for accommodating the gasket under
compression.
2.4.3.11 Earthing
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) The current density adopted for the design of terminal connector
(TC) shall in no case exceed 1.6 A/ sq mm for copper and 1.0 A/ sq
mm for terminal contactor made of other material.
iii) For conductor insulation, the insulating materials shall meet the
requirements as per IS: 4800
iv) The CT shall be provided with a rating plate with dimensions and
markings as per IS 2705. The markings shall be punched and not
painted.
v) The Current Transformer shall be filled with oil after processing and
thereafter hermetically sealed to eliminate breathing and to prevent air
and moisture from entering into the tanks. Oil filling or oil sampling
cocks, if provided to facilitate factory processing, should be
permanently sealed before despatching the Current Transformer. The
method adopted for hermetic sealing shall be described in the offer.
vi)The castings of base, collar etc. shall be die-cast and tested before
assembly to detect cracks and voids if any.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
vii) The instrument security factor of metering core shall be low enough
but not greater than 5. This shall be demonstrated on all the ratios of
the metering core, in accordance with procedure specified in IEC 185
or IS: 2705.
i) Primary winding shall be hair pin type or wound type made out of
high conductivity copper. The Contractor may also offer CT with bar
type primary with inverted arrangement of construction, if considered
more appropriate. Specific reasons for selection of a particular
metal/alloy and its merits shall be clearly brought out in the offer.
Conductors used for the primary winding shall be rigid or housed in
rigid metallic shell. Unavoidable joints in the primary winding shall be
welded type. The details of such welded joints shall be indicated in the
drawings submitted. For primary winding current densities shall not
exceed the following limits for normal current:
ii) The design density for short circuit current as well as conductivity of
the metal used for primary winding shall meet the requirement of IS
2705. The Contactor shall submit detailed calculations for selection of
winding cross sections at the time of approval of the drawings.
iii) The primary winding shall be designed for extended primary current
at 120% of rated primary current.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
nuts and washers shall be of brass, duly nickel plated. The minimum
out side diameter of the studs shall be 6 mm. The length of at least 15
mm shall be available on the studs for inserting the leads. The
horizontal spacing between centers of the adjacent studs shall be at
least 1.5 times the outside circum diameter of the nuts.
ii) The current transformer shall be provided with suitable test tap for
measurement of capacitance, tan delta as well as partial discharges, in
factory as well as at site. Provision shall be made of a screw on cap
for solid and secured earthing of the test tap connection when not in
use. A suitable caution plate shall be provided duly fixed on the cover
of the secondary terminal box indicating the purpose of the test tap and
necessity of its solid earthing as per prescribed method, before
energizing the C.T.
c) Lifting lugs
All the equipments offered, shall be fully type tested as per relevant
standards. The Employer reserves the right to demand repetition of
some or all the type tests in the presence of Employers
representatives. For this purpose the cost of the test has to be born by
the Contractor.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.4.1 General
ii)It is not the intent to specify completely herein all details of the design
and construction of equipments. However the equipment shall conform
in all respects to high standards of engineering, design and
workmanship and specifications mentioned and shall be capable of
performing in continuous commercial operation up to the Contractors
guarantee in a manner acceptable to the Employer, who will interpret
the meanings of drawings and specification and shall have the power
to reject any work or material which, in his judgment, is not in
accordance their with. The equipments offered shall be complete with
all components necessary for their effective and trouble free operation.
Such components shall be deemed to be within the scope of
Contractors supply, irrespective of whether those are specifically
brought out in this specification or not.
132 kV 33kV
v) Insulation level
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.4.5 Standards
The metal tanks shall be coated with at least two coats of Zinc rich
epoxy painting. All the ferrous hardware, exposed to atmosphere, shall
be hot dip galvanised. All other fixing nuts, bolts, washers shall be
made out of Stainless Steel
Insulating oil required for first filling of the instrument transformers shall
be covered in Contractors scope of supply. The oil shall meet the
requirements of latest edition of IS 335.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) Nuts and bolts or screws used for fixation of the interfacing porcelain
bushings for taking out terminals shall be provided on flanges
cemented to the bushings and not on the porcelain.
iiii) For gasketed joints wherever used Nitrite Butyl rubber gaskets shall
be used. The gasket shall be fitted in properly machined groove with
adequate space for accommodating the gasket under compression.
2.4.4.11 Earthing
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) The current density adopted for the design of terminal connector
(TC) shall in no case exceed 1.6 A/sq mm for copper and 1.0 A/sq mm
for T.C. made of other material.
iii) For conductor insulation, the insulating materials shall meet the
requirements as per IS: 4800
i) The P.T. shall be filed with oil after processing and hermetically
sealed to eliminate breathing and to prevent air and moisture from
entering the tanks. Method adopted for hermetic sealing shall be
described in the offer. Oil filling and/or oil sampling cocks, if provided
to facilitate factory processing shall be permanently sealed before
dispatching the P.T.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
copper cable of required size. The terminal box shall be dust and
vermin proof. Suitable arrangement shall be provided for drying of air
inside the terminal box. The dimensions of the opening of the terminal
box shall be adequate to enable easy access and working space with
the use of normal tools.
iv)The P.T. shall be provided with a rating plate with dimensions and
markings as per IS 3156. The markings shall be punched and not
painted.
All the equipments offered, shall be fully type tested as per relevant
standards. The Employer reserves the right to demand repetition of
some or all the type tests in the presence of Employers
representatives. The cost of the test shall be born by the Contractor.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.5.1 Scope
ii) It is not the intent to specify, completely here in all the details of design
and construction of the circuit breaker. However, the breaker shall
conform, in all respects to high standards of engineering, design and
workmanship as listed here-after. It shall be capable of performing in
continuous commercial operation up to the Contractors guarantee in a
manner acceptable to the Employer who will interpret the meanings of
drawings and specifications and shall have power to reject any work or
material which, in his judgment, is not in accordance therewith. The
circuit breaker so offered shall be complete with all components
necessary for its effective and trouble-free operation. Such
components shall be deemed to be within the scope of Contractors
supply, irrespective of whether those are specifically brought out in this
specification or not.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
operated, pole/three
(mechanically poles
coupled)simultaneous
operation
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
f) IS: 7311 Seamless high carbon steel cylinders for permanent and
high pressure liquefiable gases.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
o) DGMS Regulations
i) Environmental Conditions:
The rating, quality and location of electrical supply system for operation
of the circuit breaker are described below. The auxiliary electrical
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.5.7 Ratings
i) For power devices (SF6 CB) 415 V +/- 5% three phase 4 wire
(drive motors) 50 Hz Neutral grounded AC supply
ii) For AC control & Protective devices, 240 V +/- 5% , single phase, 2
lighting fixtures, space heaters wire, 50 Hz AC supply with one
and fractional h.p. motors point grounded
2.4.5.8 Standards
2.5.8.1 The circuit breaker shall conform to the latest revisions, available at the
time of placement of orders of relevant standards, rules and codes
listed at in this document. Equipments meeting with the stipulations of
equivalent IEC, ANCI, CSA, DIN standards, which ensure equal or
better quality than the standards listed in here after, shall also be
acceptable. In such case the Contractor should submit along with his
offer, two copiers of such standards in authentic English translation, if
the language of the standard is other than English. In case of dispute,
the stipulation in the English translation, submitted by the Contractor
shall prevail. Further, in the event of conflict between the stipulations
of standards adopted by the Contractor and the corresponding Indian
Standards Specification, the stipulation of Indian Standard
Specification shall prevail.
ii) The breakers will be required to break small inductive currents and line
charging current without causing excessive over voltage, and charging
current without re-strike. The breaker shall also be required to handle
evolving faults and meet the requirements regarding partial discharge,
radio interference etc, as specified in relevant standards.
i) Main contacts shall have ample area and contact pressure for carrying
the rated continuous and short time current of the breaker without
excessive temperature rise which may cause pitting or welding.
Contacts shall be adjustable to allow for wear, shall be easily
replaceable and shall have minimum number of movable parts and
adjustments to accomplish test results, Main contacts shall be the first
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
to open and the last to close so that there will be little contact burning
and wear. Tips of main contacts shall be silver plated.
ii) Arcing contacts, if provided, shall be the first to close and the last to
open and shall be easily accessible for inspection and replacement.
The arcing contacts shall have tungsten alloy tipping
iii) In the case of multi break interrupters, they shall be so designed and
augmented that a fairly uniform voltage distribution is developed across
them.
iv) The inside operating rod or insulated fiber glass connecting rods
wherever used, shall be sturdy and shall not break during the entire life
period of the breaker. The insulated rods shall have anti-tracking
quality towards electrical stresses.
ii) The breaker shall be designed to withstand the rated terminal load,
wind load/Earth quake load and short circuit forces. The short circuit
forces to be considered or the design shall be based on length of bus
bar consisting of conductors and phase to phase spacing.
iii) The current density adopted for the design of the terminal pad shall in
no case exceed 1.6A/sq .mm for copper pad and 1.0 A/sq .mm for pad
made of other material.
iv) The vertical clearance of lowest terminal pad from ground level
(including concrete foundation plinth) shall be approximately 4.6 m
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.5.15 Galvanising
All ferrous parts including nuts, bolts, plain and spring washers of M10
and above, support channels, structures, etc. shall be hot dip
galvanised to conform to latest version of IS 2629 or any other
equivalent authoritative standard. All other fixing nuts, bolts washers of
size below M 10 shall be made out of stainless steel
2.4.5.16 Earthing
i) Circuit breaker and its operating device shall be provided with rating
plate made out of photo finish type plates, marked with the following
data. The data shall be either punched or engraved on the plate and
name plate surface should be coated with colour less epoxy powder.
c) Year of manufacture
d) Rated voltage
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
o) Rated frequency
ii) The rating plates shall be installed in such positions that the same
are clearly visible to man standing on ground.
iii) The coils of operating devices shall be marked clearly with the
catalogue number/reference number as indicated in control wiring
diagram.
i) Two electrically independent trip circuits including two trip coils per
pole.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
viii) Trip circuit supervision for pre trip as well as post trip. 2 nos. per
breaker.
ix) The trip circuit supervision relays shall be capable of monitoring the
trip circuits irrespective of whether the breaker is open or closed.
i) Alarms
ii) Indications
Breaker on-off
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
a) Breaker on-off
2.4.5.21 Interlocks
2.4.5.22 Mounting
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
v) The Contractor shall furnish following details along with first lot of
Drawings to be submitted by him along with the schedule.
i) The circuit breaker shall be designed for electrical local and remote
control. In addition there shall be provision for local mechanical
control.
ii) Control cabinets shall be sheet steel enclosed and shall be dust,
water and vermin proof. Sheet steel shall be at least 2.6 mm thick
when control cabinets are specified for indoor use and at least 3.0 mm
thick when control cabinets are intended for outdoor operation. There
shall be sufficient reinforcement to provide level surfaces, resistance to
vibrations and rigidity during transportation and installation. Control
cabinets shall be provided with double hinged door and padlocking
arrangements. The door hinges shall be of union joint type to facilitate
easy removal and the distance between hinges shall not exceed 350
mm. Door shall be properly braced to prevent wobbling.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iv) Motors rated 1 kW and above being controlled from the control
cabinet would be suitable for operation on a 415V, +/- 6% , 3 phase 50
Hz system. Fractional kW motors would be suitable for operation on a
240 V , +/- 6% , 1 phase, 50 Hz AC supply system.
v) Push button shall be rated for not less than 6 Amps, 415 Volts AC or
2 Amps, 110 V DC and shall be flush mounted on the cabinet door and
provided with appropriate name plates. Red, green and amber
indicating lamps shall be flush mounted and provided with series
resistors.
vi) For motors upto 5 kW, contactors shall be direct on line, air break,
single throw type and shall be suitable for making and breaking the
stalled current of the associated motor which shall be assumed equal
to 6.5 times the full load current of the motor at 0.2 p.f. For motors
above 5 kW, automatic star delta type starters shall be provided. 3
pole contactors shall be furnished for 3 phase motors and 2 pole
contactors for single phase motors. Reversing contactors shall be
provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided.
Contactors shall be suitable for uninterrupted duty and shall be of duty
category class AC4 as defined in IS 13947. The main contacts of the
contactors shall be silver plated and the insulation class for the coil
shall be class E or better. The dropout voltage of the contactors shall
not exceed 70% of the rated voltage.
viii) Single phasing and thermal over load protection shall be provided
for all three phase motors.
ix) Power cables will be of 1100 Volt grade stranded copper conductor,
PVC sheathed single steel wire armoured FRLS type and PVC
jacketed. All necessary wiring will be complete with cable terminating
accessories such as glands, crimp type tinned copper lugs etc. for
power as well as control cables. Suitable brass cable glands shall be
provided for cable entry.
x) Wiring for all control circuits shall be carried out with 1100 Volts
grade PVC insulated tinned copper stranded conductors of sizes not
smaller than 2.5 sq. mm. Atleast 20% spare terminal blocks for control
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xiv) Items inside the cabinet made of organic material shall be coated
with a fungus resistant varnish.
i) SF6 breaker shall be so designed that upon loss of pressure the gap
between open contacts shall be adequate to withstand at least the
rated voltage at atmospheric pressure of gas.
ii) The Contractor shall clearly bring out in his offer the precautions to
be taken in the use of SF6 breaker
iii) Following features shall be provided for monitoring of SF6 gas in the
breaker:
a) SF6 gas density meter with two potential free contacts of suitable
rating. One of these contacts shall be used for annunciation of low
density. The other contact shall be used to ensure breaker lockout in
the event of low SF6 gas density. The Contractor shall furnish a chart
showing relation between pressure and density of SF6 gas, as well as
settings for alarm and lockout.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iv) Closing coil shall operate correctly at all values of voltage between
85% and 110% at the rated control voltage and trip coil shall operate
correctly at all values of voltage between 70% and 110% of the rated
control voltage as specified elsewhere
v) The Contractor shall furnish along with the offer, detailed Schematic
drawings showing all types of control, protection, monitoring schemes
to be employed by him. The Contractor shall be required to modify the
schemes, if necessary, after discussions with the Employer.
2.4.5.27 Tests
i) Type Tests
d) The Employer reserves the right to conduct tests included in the list
of type tests on requisite number of samples/items at Contractors cost
in the presence of Employers representative. If the
equipment/material does not withstand the type test, then the
equipment/material supplied will be liable for rejection. The Contractor,
in such an eventuality, shall be allowed to modify the equipment and
type test the same again at his cost in the presence of the Employers
representative. These type tests shall however the conducted by the
Contractor within a reasonable time. After successful passing of the
type tests, all the equipments/material supplied shall be modified in line
with the equipment/materials which have successfully passed the type
test. In case Contractor fails to carry out the type test within
reasonable time or does not agree to carry out the type test at his cost,
his equipment/material supplied earlier shall be rejected and payments
made earlier for these equipment shall be recovered by the Employer.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.5.28 Drawings
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
1 2 3 4
----------------------------------------------------------------------------------------------------------------
1. Contacts (see note 3)
Bare copper and bare
Copper alloy
- in air 75 25
- in SF6 90 40
( Sulpuer Hexafluoride)
- in oil 80 30
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
- bare 90 40
Notes:
1) According to its function, the same part may belong to several categories
as listed in table. In this case the permissible maximum value of
temperature and temperature rise to be considered are the lowest amount
of the relevant categories.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
4) The quality of the coated contacts shall be such that a layer of coating
material remains at the contact area:
5) For fuse contacts, the temperature rise shall be in accordance with IEC
publications on High Voltage Fuses.
7) When materials other than those given in table are used, their
properties shall be considered, notably in order to determine the
maximum permissible temperature rises.
8) The values of temperature and temperature rise are valid even if the
conductor connected to the terminals is bare.
10) Special consideration should be given when low flash point oil is used
in regard to vaporization and oxidation.
11) The temperature shall not reach a value where the elasticity of the
material is impaired.
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iii) Electric strength: Two and one half times that of Nitrogen
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
Water 15 ppm.
x). Tests:
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.6.1 Scope
ii) It is not the intent to specify, completely here in all the details of design
and construction of the circuit breaker. However, the breaker shall
conform, in all respects to high standards of engineering, design and
workmanship as listed here-after. It shall be capable of performing in
continuous commercial operation up to the Contractors guarantee in a
manner acceptable to the Employer who will interpret the meanings of
drawings and specifications and shall have power to reject any work or
material which, in his judgment, is not in accordance therewith. The
circuit breaker so offered shall be complete with all components
necessary for its effective and trouble-free operation. Such
components shall be deemed to be within the scope of Contractors
supply, irrespective of whether those are specifically brought out in this
specification or not.
v) Type Vacuum
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m) DGMS Regulations
i) Environmental Conditions:
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
The rating, quality and location of electrical supply system for operation
of the circuit breaker are described below. The auxiliary electrical
equipments provided by the Contractor for specific operation of the
circuit breaker, shall be suitable for operation on the same.
2.4.6.6 Ratings
ii) For AC control & Protective devices, 240 V +/- 5% , single phase, 2
lighting fixtures, space heaters wire, 50 Hz AC supply with
one point grounded
2.4.6.7 Standards
The circuit breaker shall conform to the latest revisions, available at the
time of placement of orders of relevant standards, rules and codes
listed at in this document. Equipments meeting with the stipulations of
equivalent IEC, ANCI, CSA, DIN standards, which ensure equal or
better quality than the standards listed in here after, shall also be
acceptable. In such case the Contractor should submit along with his
offer, two copiers of such standards in authentic English translation, if
the language of the standard is other than English. In case of dispute,
the stipulation in the English translation, submitted by the Contractor
shall prevail. Further, in the event of conflict between the stipulations
of standards adopted by the Contractor and the corresponding Indian
Standards Specification, the stipulation of Indian Standard
Specification shall prevail.
ii) The breakers will be required to break small inductive currents and line
charging current without causing excessive over voltage, and charging
current without re-strike. The breaker shall also be required to handle
evolving faults and meet the requirements regarding partial discharge,
radio interference etc, as specified in relevant standards.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
i) Main contacts shall have ample area and contact pressure for carrying
the rated continuous and short time current of the breaker without
excessive temperature rise which may cause pitting or welding.
Contacts shall be adjustable to allow for wear, shall be easily
replaceable and shall have minimum number of movable parts and
adjustments to accomplish test results, Main contacts shall be the first
to open and the last to close so that there will be little contact burning
and wear. Tips of main contacts shall be silver plated.
ii) Arcing contacts, if provided, shall be the first to close and the last to
open and shall be easily accessible for inspection and replacement.
The arcing contacts shall have tungsten alloy tipping
iii) In the case of multi break interrupters, they shall be so designed and
augmented that a fairly uniform voltage distribution is developed across
them.
iv) The inside operating rod or insulated fiber glass connecting rods
wherever used, shall be sturdy and shall not break during the entire life
period of the breaker. The insulated rods shall have anti-tracking
quality towards electrical stresses.
ii) The breaker shall be designed to withstand the rated terminal load,
wind load/Earth quake load and short circuit forces. The short circuit
forces to be considered or the design shall be based on length of bus
bar consisting of conductors and phase to phase spacing.
iii) The current density adopted for the design of the terminal pad shall in
no case exceed 1.6A/sq .mm for copper pad and 1.0 A/sq .mm for pad
made of other material.
iv) The vertical clearance of lowest terminal pad from ground level
(including concrete foundation plinth) shall be approximately 3.7 m.
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2.4.6.14 Galvanising
All ferrous parts including nuts, bolts, plain and spring washers of M10
and above, support channels, structures, etc. shall be hot dip
galvanised to conform to latest version of IS 2629 or any other
equivalent authoritative standard. All other fixing nuts, bolts washers of
size below M 10 shall be made out of stainless steel
2.4.6.15 Earthing
i) Circuit breaker and its operating device shall be provided with rating
plate made out of photo finish type plates, marked with the following
data. The data shall be either punched or engraved on the plate and
name plate surface should be coated with colour less epoxy powder.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
c) Year of manufacture
d) Rated voltage
o) Rated frequency
ii) The rating plates shall be installed in such positions that the same
are clearly visible to man standing on ground.
iii) The coils of operating devices shall be marked clearly with the
catalogue number/reference number as indicated in control wiring
diagram.
i) Two electrically independent trip circuits including two trip coils per
pole for 33 kV circuit breakers.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
viii) Trip circuit supervision for pre trip as well as post trip. 2 nos. per
breaker for 33 kV.
ix) The trip circuit supervision relays shall be capable of monitoring the
trip circuits irrespective of whether the breaker is open or closed.
i) Alarms
ii) Indications
Breaker on-off
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
a) Breaker on-off
2.4.6.20 Interlocks
2.4.6.21 Mounting
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
v) The Contractor shall furnish following details along with first lot of
Drawings to be submitted by him along with the schedule.
i) The circuit breaker shall be designed for electrical local and remote
control. In addition there shall be provision for local mechanical
control.
(iii) The mechanism shall be provided with motor starter fitted with
overload release, auxiliary switches and socket for inspection lamp.
The charging for springs shall be done by a 240 V AC single phase
motor. The remote control switch will be provided on the control panel.
Closing and tripping devices shall operate at 110 V DC. It is envisaged
that C.T. operated direct acting trip coil will also be fitted for reliable
operation. Some of the important precautions required are mentioned
below :
- the spring, if charged, can not be released when the circuit breaker is
closed.
- Interlock shall be provided to prevent slow closing or opening of the
circuit breaker in its service position.
- If the spring fails, it should be possible to close the circuit breaker
manually.
- It should be possible to recharge the spring automatically while the
circuit breaker is closed, thus preparing in advance for the next closing
operation.
- Necessary limit switches shall be incorporated in the automatic spring
charging circuit. The release of the spring shall be electrically operated
coil for remote control. An emergency hand release should be provided
to work in case of power supply failure.
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The vacuum interrupter should enable the metal vapour for arch
discharge through the plasma and is extinguished near current zero.
The conductive metal vapour should condense within a few micro
second leading to the rapid build up of dielectric strength across the
open contact gap.
vi) The operating mechanism shall be anti pumping and trip- free.
There shall be no rebounds in the mechanism and it shall not require
any critical adjustments at site. Operation of the power operated
closing device, when the circuit breaker is already closed, shall not
cause damage to the circuit breaker or endanger the operator.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) Control cabinets shall be sheet steel enclosed and shall be dust,
water and vermin proof. Sheet steel shall be at least 2.6 mm thick
when control cabinets are specified for indoor use and at least 3.0 mm
thick when control cabinets are intended for outdoor operation. There
shall be sufficient reinforcement to provide level surfaces, resistance to
vibrations and rigidity during transportation and installation. Control
cabinets shall be provided with double hinged door and padlocking
arrangements. The door hinges shall be of union joint type to facilitate
easy removal and the distance between hinges shall not exceed 350
mm. Door shall be properly braced to prevent wobbling.
iv) Motors rated 1 kW and above being controlled from the control
cabinet would be suitable for operation on a 415V, +/- 6% , 3 phase 50
Hz system. Fractional kW motors would be suitable for operation on a
240 V , +/- 6% , 1 phase, 50 Hz AC supply system.
v) Push button shall be rated for not less than 6 Amps, 415 Volts AC or
2 Amps, 110 V DC and shall be flush mounted on the cabinet door and
provided with appropriate name plates. Red, green and amber
indicating lamps shall be flush mounted and provided with series
resistors.
vi) For motors upto 5 kW, contactors shall be direct on line, air break,
single throw type and shall be suitable for making and breaking the
stalled current of the associated motor which shall be assumed equal
to 6.5 times the full load current of the motor at 0.2 p.f. For motors
above 5 kW, automatic star delta type starters shall be provided. 3
pole contactors shall be furnished for 3 phase motors and 2 pole
contactors for single phase motors. Reversing contactors shall be
provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided.
Contactors shall be suitable for uninterrupted duty and shall be of duty
category class AC4 as defined in IS 13947. The main contacts of the
contactors shall be silver plated and the insulation class for the coil
shall be class E or better. The dropout voltage of the contactors shall
not exceed 70% of the rated voltage.
viii) Single phasing and thermal over load protection shall be provided
for all three phase motors.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ix) Power cables will be of 1100 Volt grade stranded copper conductor,
PVC sheathed single steel wire armoured FRLS type and PVC
jacketed. All necessary wiring will be complete with cable terminating
accessories such as glands, crimp type tinned copper lugs etc. for
power as well as control cables. Suitable brass cable glands shall be
provided for cable entry.
x) Wiring for all control circuits shall be carried out with 1100 Volts
grade PVC insulated tinned copper stranded conductors of sizes not
smaller than 2.5 sq. mm. Atleast 20% spare terminal blocks for control
wire terminations shall be provided on each panel. The terminal blocks
shall be similar ELMEX type CAT-44 or better type. All terminals shall
be provided with ferrules indelibly marked or numbered and these
identifications shall correspond to the designations on the relevant
wiring diagrams. The terminals shall be rated for adequate capacity;
which shall not be less than 10 Amps.
xiv) Items inside the cabinet made of organic material shall be coated
with a fungus resistant varnish.
2.4.6.25 Tests
i) Type Tests
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
d) The Employer reserves the right to conduct tests included in the list
of type tests on requisite number of samples/items at Contractors cost
in the presence of Employers representative. If the
equipment/material does not withstand the type test, then the
equipment/material supplied will be liable for rejection. The Contractor,
in such an eventuality, shall be allowed to modify the equipment and
type test the same again at his cost in the presence of the Employers
representative. These type tests shall however the conducted by the
Contractor within a reasonable time. After successful passing of the
type tests, all the equipments/material supplied shall be modified in line
with the equipment/materials which have successfully passed the type
test. In case Contractor fails to carry out the type test within
reasonable time or does not agree to carry out the type test at his cost,
his equipment/material supplied earlier shall be rejected and payments
made earlier for these equipment shall be recovered by the Employer.
2.4.6.26 Drawings
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
4) The quality of the coated contacts shall be such that a layer of coating
material remains at the contact area:
5) For fuse contacts, the temperature rise shall be in accordance with IEC
publications on High Voltage Fuses.
7) When materials other than those given in table are used, their
properties shall be considered, notably in order to determine the
maximum permissible temperature rises.
8) The values of temperature and temperature rise are valid even if the
conductor connected to the terminals is bare.
10) Special consideration should be given when low flash point oil is used
in regard to vaporization and oxidation.
11) The temperature shall not reach a value where the elasticity of the
material is impaired.
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a) In oil : 50 deg. C
b) In winding : 55 deg. C
2.4.7.3 Tests
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
v) Special Tests
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iii) The transformer design shall take care of the starting load of
the above large equipment
i) Oil conservator with oil level gauge, drain valve and filling
holes with air tight cap.
v) Double float Bucholoz relay with valves for two sides and with
potential free alarm and trip contacts wired upto the marshalling
box. The approach facility and inspection facility should be
provided for bucholoz relay with live transformer.
vi) Oil sampling device for the tank top and bottom oil sampling
with valves.
vii) Magnetic oil level gauge/indicator with low oil level alarm
contacts.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xv) Under carriage suitable with jacking pads and with hauling
holes/hook.
xviii) Lifting lugs and transport lugs for the complete transformer.
xix) Air release device and plugs at the top of the transformer
and busing turrets.
xxii) Supervisory alarm and trip contacts for gas operated double
float relay.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) All the details as per Schedule of this volume should be duly filled in
and submitted along with the offer.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.7.8 Insulation
ii) The coils and shield provided shall be so dimensioned that they form
number of substantially equal capacitance in series, thus ensuring
relatively uniform distribution through the winding of surge voltages as
well as power frequency voltages.
i) Core: It shall be built up from cold rolled grain oriented Silicon alloy
steel of the best magnetic properties. Debarring process shall be duly
carried out, so that it will build into a core with a high space factor, low
loss and maximum reliability. Lamination shall be annealed to relieve
cutting and piercing strain wherever required. To further lower iron
losses, laminations are mitered and core bolts for clamping are kept to
minimum. Further, manufacturing details on core shall be submitted by
Tenderer. All structural steel work associated with the core is shot
blasted to remove scales, and coated with oil proof varnish.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
a) Oil immersed tap selector and arcing switch provided with resistor.
iii) The tap changer shall be designed such that the contacts do not
interrupt arcs within the main tank of the transformer. The oil filled
compartment of tap selector switch shall be provided with means of
releasing the gas produced due to arcing. It shall be designed so as to
prevent the oil of tap selector compartment from mixing with the oil of
the transformer compartment from mixing with the oil of the transformer
tank. Operating mechanism of OLTC shall be designed such that only
one step is actuated by each command and subsequent step is
actuated by new or repeat command.
iv)The transformer shall give full load output at all taps. The tap
changer shall be provided with out of step protection.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
i) The control/relay panels (CR panel) shall be simplex type suitable for
indoor installation. The cubicles shall be free-standing, floor mounting
type, and shall be made of rigid structural frames enclosed completely
with specifically selected, smooth finished rolled sheet steel of
thickness not less than 3 mm (min.) for front of control panels and 2.5
mm (min) for sides, top and bottom portions as well as doors. There
shall be sufficient reinforcement to ensure level surfaces, resistance to
vibration and rigidity during transportation, installation and operation.
The cubicles shall be vermin, dust and moisture proof and shall provide
degree of protection not less than IP: 31 as per IS: 12036.
ii) All sheet steel works shall be properly phosphated and treated as per
the relevant standards. The cubicles shall be finally painted by powder
coating process or by oven baking process. The colour shade for final
paint shall be Light Grey to shade no. 631 as per IS-5 for both interior
and exterior surfaces.
iv) All wiring shall be carried out with 660 V grade single core multi-strand
flexible copper conductor wires with PVC insulation. Colour coded
wires shall be used for CT/PT circuits. Wiring troughs shall be used for
routing the cables. Ferrule numbers shall be provided at both ends of
cable and the ferrule numbering shall correspond to the numbering in
the approved schematic drawings.
vi) The overall dimensions of the control and relay panel shall be suitably
and appropriately designed by the Tenderer. The relay panels shall be
modular rack-mounting type in accordance with relevant standards.
The protective relays shall be drawout / plug in type as far as possible.
Non-draw out type relays and ancillary components like switches,
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
viii) All control switches and instrument switches shall be rotary type, with
escutcheon plates clearly marked to show the operating positions.
ix) Semaphore indicators with mimic diagram shall be provided for actual
status indication (ON/OFF) of isolators and circuit breakers.
c) Earth - Black
xi) Static annunciators suitable for visual and audible alarm annunciation
shall be provided on the control panel. Annunciator fascia units shall
have translucent plastic windows for each alarm point. Annunciator
shall be provided with Accept/Reset/Lamp test push buttons. One bell
for trip alarm and one buzzer for non-trip alarm shall be provided for
each annunciation scheme. Visual alarm shall continue to glow till the
abnormality is cleared. Provision for testing of healthiness of visual &
audio alarm shall be provided.
xii) It shall be ensured that spurious/nuisance alarm does not occur due to
influence of external magnetic field or switching disturbances from
neighboring circuits within the panel.
xiii) Auxiliary supply available for the C&R panels will be as follows:
xiv) All the indicating instruments shall be of suitable. size. All 132
kV and 33 kV meters shall be digital microprocessor based power
meters for various data display with memory for storing data. Meters
shall be provided with TTB (Testing Terminal Board). The meters shall
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
have long life and reliability. For this supporting literatures and test
certificates shall be provided with the offer.
ii) In transformer relay panels, auxiliary relays (self reset type with hand
reset flags) shall be provided for supervisory functions of transformer
buchholz, WTI, OTI, etc.
iii) In the control and relay panels, separate fuses are to be provided for
various sub-circuits, as per standard practices. Each of these fuses
shall be supervised using suitable auxiliary relays and an alarm shall
be sounded when failure of any fuse takes place. The DC supervision
scheme is to be suitably designed so that failure of 110V DC supply will
be announced through a hooter and indicating lamp.
v) Each control panel shall have individual fire extinguisher inside the
panel with auto sensor.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.9.1 The station transformer shall be outdoor type, mineral oil immersed,
core type, Copper wound, three phase step down transformer, suitable
for solidly grounded system. The winding shall be uniformly insulated.
The transformer shall conform to IS: 2026 and IS: 6600 (latest). The
temperature rise shall be as specified in IS specifications. Provision of
+7.5% to -7.5% in 7 steps of 2.5% tappings shall be made on the HV
winding. These tappings shall be controlled by an externally operated
OFF CURCUIT tap changing gear capable of being locked in position.
Two separate earth terminals shall be provided on the body of the
transformer for transformer earthing. The transformer shall be supplied
with first filling of transformer oil as per IS: 335 of 1972.
2) Rated voltage
HV nominal : 33 kV RMS
3) No. of phases : 3
4) Frequency : 50 Hz
5) Application : Outdoor
8) Vector group : DY 11
9) Insulation of winding
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
a) In oil : 50 deg. C
b) In winding : 55 deg. C
x) Explosion vent
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.9.4 Tests
i) The offer shall include all test certificates as required by IS and Indian
Electricity Rules
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
i) This shall be of indoor type and suitable for 415 V, 3 phases, 50 Hz,
solidly earthed neutral system with a fault level of 35 MVA.
ii) The incoming feeders and sectionaliser control will be by Moulded case
circuit breaker with back up HRC fuse.
iii) All the incoming panels shall have digital type ammeter, voltmeter,
power factor meter and frequency meter. Other panels shall have
ammeter only.
iv) The out going feeder at power distribution board feeding power to the
lighting distribution board and load 5kW & above shall be controlled by
3 pole Moulded Case circuit breaker with backup HRC fuses.
v) All other feeders shall be provided with 4 pole/ 2 pole MCBs of suitable
rating with backup HRC fuses.
vi) All motor control feeders shall be provided with independent single
phasing protection.
vii) 10 % of spare out lets for each type (minimum one) shall be provided.
ii) The distribution board shall be free standing, floor mounting, multi tire
(4 compartments), cubicle type, single front, non draw out type. The
enclosure shall be dust, vermin and weather proof type. The enclosure
shall have a degree of protection not less than IP 52. The board shall
have provision of cable entry from the bottom.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iii) The distribution board shall be fabricated from not less than 2 mm thick
steel sheet and properly stiffened. All panel edges and cover / door
edges shall be properly stiffened against distortion by rolling, bending.
The supporting structure shall be free from flaws, twists and bends.
Rear side of the distribution boards will be covered by removable
bolted covers. The hinged doors provided in the front shall be provided
with proper locking facility and rubber gaskets all around. Proper inter
locking arrangement shall be provided so that incoming MCCBs is
brought to OFF position before the door is opened. The minimum
clearance between the floor and bottom of the panel shall be 500mm
and is covered from the front and end sides by detachable MS sheet.
The structural steel shall be properly surface treated. Two coats of lead
primer shall be applied first over which two coats of synthetic enamel
paint shall be applied for a smooth and elegant surface. The operating
handles, meters, required labels, danger plates shall be provided on
front door of the board.
iv) The board shall consist of number of panels for feeding power to
various loads. Each panel shall be of maximum 4 tire formation. The
bottom compartment shall house terminal blocks for terminating cables.
An earth bus shall be provided in this compartment and extended
throughout the length of the board. The earth bus shall have sufficient
cross section to carry the momentary short circuit and short time fault
currents occurred in the system to the earth. The panel shall have two
earth terminals. The earth bus shall be made of galvanised steel.
Vertical earth bus shall be provided in each panel.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
vii) The outgoing feeder for lighting distribution board, load 5kW and above
shall be controlled by MCCB with backup HRC fuse. All other outgoing
feeders shall be controlled by 4/2 pole MCB with back up HRC fuse. All
out going feeders shall be provided with earth leakage protection.
Motor protection relay shall be provided for comprehensive protection
to the motors.
viii) One set of indicating lamps of LED type shall be provided in the front
panel of cubicle for indicting the status.
ix) All the internal wiring shall be carried out in the factory with 660 V
grade, single core, 2.5 sq. mm or larger cross section as per
requirement. The cables shall be PVC insulation type with copper
conductors. Extra flexible wires shall be used for wiring various devices
mounted on hinged doors. All wiring shall be properly supported, neatly
arranged, readily accessible and securely connected to the equipment
terminals and terminal blocks. Internal terminations of standard
conductors shall be made with solder less crimping type tinned copper
lugs which shall finally grip the conductors. Insulating sleeves shall be
provided on exposed lugs or joints. Proper ferrules shall be provided
for identification of wiring
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
The outgoing modules shall have MCBs with backup HRC fuses:
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
The lighting distribution board shall be of indoor type and suitable for
operation at 230 V (L-L), 50 Hz supply system. These specifications
shall be read in conjunction with scope of work/supply.
The distribution board shall be fabricated from sheet steel not less than
2mm thick and properly stiffened. The enclosure of distribution boards
shall be weather, dust and vermin proof. The door of the board shall
be provided with pad locking arrangement. The board shall be
adequately surface treated and painted with double coat synthetic
enamel paint after application with two coats of red oxide primer. The
distribution boards will be suitable for mounting on wall as well as on
pedestals. The distribution boards will be of front opening type.
2.4.11.3 The MCCB s / MCB s shall have built in overload and short circuit
protections. The MCCB will have short circuit breaking capacity of
35kA and MCB will have short circuit breaking capacity of 9kA. The
MCCB will be of 3 pole type, whereas MCB will be of two poles. The
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.11.4 The MCCB/MCB s shall be of quick make, quick break, current limiting
type having trip free mechanism. These shall be provided with
magnetic release which will protect the circuit against short circuit. The
operating lever shall give a clear trip indication and shall be suitable for
interlocking with cubical door. The MCCBs shall ensure operating of all
the three phases in case of a fault in one phase.
.
2.4.11.5 All the components and the boards shall conform to relevant
Indian Standards.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
i) The Direct Current supply system shall comprise one set of 110 V ,
200 AH (minimum) sealed maintenance free battery along with
associated float and boost charger (two numbers, one working and one
standby) and distribution boards for supplying 110 V DC for control,
protection, breaker tripping, indications etc.
ii) The charger unit shall be suitable for initial charging, float charging and
boost charging of the battery set concerned. The unit shall be in fully
assembled and completely wired up condition with all the equipments
and accessories fitted in place.
iii) The battery shall be suitable for indoor operation (station type), with
ready grouped plates. The battery shall comprise the required number
of series connected standard 2 volts HDP lead-acid cells.
iv) The inter-connectors (inter-cell and internal cell as also inter row/inter
tier) shall be of lead plated copper.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.12.2 Float cum boost Charger and DC Distribution Board (DCDB) for
110 V Battery
i) This unit shall comprise two float charger cum boost charger (one
working and one standby) and two nos. distribution board along with
necessary controls, indication, annunciation and accessories. The unit
shall be made of sheet steel of 14 gauge thickness, and shall have
appropriate and required dimensions.
ii) The sheet steel used for charger cubicle shall be properly surface-
treated before painting. The final shade of paint shall be Light
Admiralty Grey, shade no. 697 as per IS:5., Powder coating process
or, alternatively oven baking process may be adopted for painting. The
enclosure shall provide degree of protection not less than IP:42 in
accordance with IS:12063.
iii) Float cum boost charger shall incorporate silicon controlled rectifiers
along with semiconductor fuses. It shall be possible to use the boost
charger in constant voltage mode also so as to use it as a float charger
in case the main float charger fails. In constant current mode, it shall
have a current stability of +/- 2% of the set value. The constant
current setting shall have step less range variable between 20% and
100% of the rated current. Both the float and boost units shall have
provision for manual setting of the required settings in addition to the
automatic regulator.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iv) The float charger and boost charger shall have current rating of 10 A,
and 20 A respectively. During normal condition the battery will be
floated across the float charger at 2.16 V per cell (+/- 1%), and the
station DC requirement shall be met by the charger.
v) The float and boost charger circuits shall be provided with filtering
devices to limit the ripple content to 5%. Suitable interlock using a DC
contactor and reverse blocking diodes shall be provided so as to
ensure that during boost charging of battery, the float charging circuit is
not connected to the battery, but operates independently feeding to the
station DC loads.
vi) The annunciation scheme shall be fascia window type, and shall have
required number of points for various alarms. Annunciation scheme
shall incorporate static components and circuitry and shall have reset
alarm feature.
ix) The 110 V rating charger cum DCDB unit (2 nos.) shall be complete
with all the components and accessories including, but not limited to,
the following:
2 4 nos. 96 sq mm DC Ammeter
c) 40-0-100A Charge/discharge
current of battery.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
6. Indicating lamps
7. 5 nos. MCB/MCCB
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
Main transformer shall be dry type double wound, natural air cooled
having continuous rating of at least 125% of the rating of the charger.
Class of insulation shall be class B but, the temperature rise shall be
limited to as that of class A insulation in accordance with IS:4540.
Reactance of the transformer shall be suitable to take care of
regulation and surge.
2.4.12.4 Battery
ii) The battery shall be suitable for indoor operation and shall be open
type (without cover) with ready grouped plates.
iv) Cell containers shall be of unbreakable poly carbonate type and shall
be sufficiently robust and free from flaws/manufacturing defects.
v) Cell lids shall be of drop on type together with suitable rubber or plastic
gasket as per relevant clause of IS: 1951-1891.
vi) The inter-cell and internal cell connectors shall be lead plated copper
having minimum thickness of 4 mm and sufficient cross section to carry
the high currents.
vii) The positive (+ve) and negative (-ve) terminal posts shall be clearly
and neatly marked for easy identification. Nuts and bolts for
connecting the cell shall be of brass having effective coating of lead.
ix) Battery racks and stand shall be constructed out of seasoned and
matured teak wood of sufficient cross-section. These shall be painted
with at least 3 coats of acid resistant paint. The racks shall be rigid,
free standing type and free from warp and twist. The assembled racks
shall be suitable for being bolted end to end to form a continuous row if
required,.
x) All cells shall be suitable numbered with number plates and fixing pins.
NIT 688 dtd 17.09.14 Job No.502255 (VOL II) Page no- 126
Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xi) One DC voltmeter having scale of -3v to +3v with suitable leads for
measuring cell voltages shall be provided.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
415 volt power cable shall be of 1100 volt grade, copper stranded
conductor, PVC insulated and PVC sheathed single layer armoured
suitable for solidly earthed neutral system.
Lighting cable shall be of 1100 volt grade, stranded copper conductor,
PVC insulated and PVC sheathed single layer armoured.
Control cable shall be of 1100/660 volt grade, multi core copper
conductor, PVC insulated and PVC sheathed, single layer armoured
having a minimum size of 2.5 square mm.
The individual cores of cable shall be identified by different coloured
insulation. For control cables having more than 4 cores, it is preferable
to provide the core number embossed on each individual core.
2.4.15.3 Sizes and Lengths
The cable size and type for 415 volts system shall be selected in
accordance with the system requirements and customer approval.
Bidder shall indicate the size and length of cables necessary to tie up
all the equipment under their scope of supply. However, during
erection if it is found that the quoted lengths are not adequate, the
Bidder shall have to supply the additional quantities to complete their
erection at no extra cost.
Size of the power and lighting cables shall be based on the following
consideration -
a) Short circuit withstand for 1 second.
b) Voltage drop - the maximum allowable voltage drop in the cable
shall not exceed 5% under full load normal working condition and 15%
under starting conditions for the highest and/or most distant located
load.
Length of cables shall be ascertained from the layout drawing so that
straight through cable joints are avoided.
De-rating factors for various conditions of installation including the
following
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
for all type of cables shall be considered while choosing the conductor
sizes:
a) Variation in ambient air temperature
b) Variation in ground temperature
c) Depth of laying
d) Soil resistively
e) Grouping of cables.
De-rating factors selected shall be based on factors recommended by
reputed cable manufacturers/ IS. The factors considered shall be
clearly brought out in the offer. If it is found that the de-rating factors
considered are not adequate, the Bidder shall have to revise his cable
sizes at no extra cost to the customer satisfaction. The overall de-
rating factor shall not exceed 0.6 in any case.
2.4.15.4 Special Cables
Special cables including but not limited to the following:
a) temperature detectors to the selector switches,
b) temperature indicators, from coal bunker level,
c) indicator temperature detectors to associated electronic
enclosure, etc.
These cables shall be heavy duty fire retarding self extinguishing,
colour coded, shielded, armoured copper conductor 650/1100 volts
grade coaxial screwed compensating mineral insulated etc.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
mast during the raising and lowering operation of the carriage. The
entire lantern carriage shall be hot dip galvanised after fabrication.
A weather proof junction box made of cast aluminum or any other
suitable material shall be provided on the carriage assembly as
required from which the interconnections to the flood light luminaries
and control gears fixed on the carriage will be made. The connections
shall be by means of PVC flexible cables of 3 cores, 1.5 sq mm.
For the installation and maintenance of the luminaries and lamps it will
be necessary to lower and rise the lantern carriage assembly. To
enable this suitable wire rope winch along with head frame assembly
shall be provided.
A suitable terminal box shall be provided at base compartment of the
high mast for terminating the incoming cable. The electrical connection
from the bottom to the top shall be made by special trailing cable
having flexibility and endurance. This shall have inbuilt facilities for
testing the luminaries while in lowered position.
Suitable earthing terminals shall be provided at convenient location on
the base of the mast for lighting and electrical earthing of the mast.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iii) Provide sufficient air gap to give the required electrical characteristics
and withstand values.
iv) Shall provide enough total creepage and protected creepage distance
(not limited to the creepage distance as indicated elsewhere) to
operate in polluted (coal dust laden) atmosphere.
iii) The post insulator shall be provided with cap of high grade
malleable steel casting. It shall be machine-faced and hot dip
galvanized. The castings shall be free from blow-holes, cracks and
such other defects. All necessary nuts, bolts, washers etc. required for
the assembly of the insulator stack shall be hot-dip galvanized and also
shall form a part of each insulator unit.
v) The ball pins shall be made of drop forged steel. All the ferrous
parts (caps, pins etc.) shall be duly hot-dip galvanised. The security
clips shall be made of phosphor bronze or stainless steel.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
vi) Cement used as filler material shall be quick setting, fast curing
portland cement. It shall not cause fracture by expansion or loosening
by contraction. Cement shall not react chemically with metal parts in
contact with it and its thickness shall be as small and as uniform as
possible.
vii) Each insulator shall be legibly and indelibly marked to show the
following
c) Electro-mechanical strength in kN
d) Country of manufacture
i) Tension type (Dead end) disc insulators shall be ball and socket type
each with a R type security clip. The color of the unit shall be brown
or dark brown. It shall be made of homogenous and vitreous porcelain
of high mechanical and dielectric strength. The ball and socket will
generally conform to IS: 2486- Part II.
ii) Each insulator shall be legibly and indelibly marked to shown the
following
c) Electro-mechanical strength in kN
d) Country of manufacture
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.17.4 Tests
i) For both post type and tension type insulators as described above
suitable number of individual units and complete strings/slacks shall be
subjected to tests in accordance with IS:731-1971 with any
amendments made from time to time and upto date. Type test reports
recently carried out i.e. max. 3 yrs. Prior to the date of opening of the
tender, shall be submitted for individual and string/slack insulators.
However, the Employer reserves the right to carry out the type test for
the samples at the cost of the Contractor if decided by the Employer
and in the presence of the Employers authorised representative.
1. Mechanical
2. Electrical
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
a)Application:-
The system shall be capable of detecting various types of fires that are
likely to occur due to electrical short circuits, burning of false ceilings,
wooden panels, paper, oil, grease, coal etc. in the substation. The
system shall be capable of providing signals to initiate alarms (both
audio and visual) and initiate operation of fire pump and audible
signals. The system shall consist of fire detection units, alarm system,
control and indicating system (PLC based), associated cabling etc.
b) Duty condition: -
c) Scope:-
The system shall comply with all the latest applicable statutory rules,
regulations, acts and safety codes which may be in force during the
period of execution and which are related with design and construction
of equipment in the locality where it is to be installed. The statutory
regulations are
i) Smoke detectors
ii) Heat detectors
iii) Central control and indicating equipment (PLC based)
iv) Alarm system
v) Annunciating panel
vi) Backup power supply
vii) Required power cable, power distribution, control cables
etc.
viii) Any other items which are required for the efficient
operation of the system and not listed above.
d) System Requirements:-
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
iii) The system shall be designed and laid in such a way that it will
help to reduce the resultant loss by reducing the delay between
ignition and the start of effective fire fighting.
vii) The heat detectors shall be of linear type non- integrating and
responds to the temperature of gases in the vicinity. The
detectors may be combination of fixed temperature element type
or rate of rise temperature elements. The heat detectors shall
comply with IS: 2175. The operating temperature shall be at
least 30 degree above the maximum anticipated ambient
temperature of 50C.
ix) The sensors and call points shall be properly designed for easy
identification, so that there may not be any difficulty in identifying
the zones from which signals have been received.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xii) The central control panel shall be of PLC type. This shall consist
of equipment for the reception of signals from the automatic
detectors and any other signals in the system as needed are
received and commands are given for audio-visual alarm, the
LED shall light up on the panel indicating system 'ON' leaving all
LED's of control panel 'OFF'. The control panel/mimic panel
shall show all the fire protection devices.
xv) The indications on the control panel shall be through LED's and
such that they can be easily, quickly and unambiguously relate
to the position of fire in the plant i.e. sector/zone from where
alarm has originated.
xix) The panel audible alarm can be silenced by accept push button.
However, the visual indication shall remain on. After taking the
corrective action of fire and when the situation becomes normal,
the system can be reset to its normal position by RESET push
button. However, the alarm shall be re-activated in presence of
smoke/heat in the affected area and can be reset only after the
cause of alarm completely removed. In case the fire spreads to
another area, the panel audible alarm shall reactivate and the
LED's of the affected area light up with the help of respective
alarm facility provided in the panel.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xxiii) The cables used for wiring the various components in the fire
alarm system shall be PVC insulated copper conductor cables
having minimum 1 sq. mm cross sectional area conforming to IS
694.
xxvii) Overhead lines shall not be used for interconnecting fire alarm
system. These shall be through u/g cables according to IS 1255.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
ii) The control panel shall be micro-processor based and fully field
programmable. It shall have sufficient memory to support its operating
system and data bases including fire management, alarm
management, historical and trend data, maintenance support
applications, operator's unit etc. It shall consist of the following:
- Central processing unit
- Built in printer
- Power supply arrangement (Built in battery charger)
- Fire alarm initiating and indicating devices
- Visual display unit
- Cables and accessories to make the operating system complete
iv) It shall have facility to process the input signal and also to control all
the input data received from detectors, manual call points and other
field devices and switches.
vi) The audible and visual alarm state shall be maintained by the
repeater and main control panel without a continued signal from the fire
detectors. The sound characteristics of the alarm shall be similar
throughout the protected premises.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
viii) In case, the alarm in the first instance is not acknowledged on main
control panel within 60 seconds, a general evacuate alarm shall sound
on all protected areas.
xi) At the main control panel fault warning shall be given for the
following occurrence:
xii) It shall have distinct earth fault indication on the loop wiring.
xiii) It shall have provision for isolation of different loops inside the
panel not accessible to the outside people and whenever isolation is
used, visible indication shall be given on the panel.
xiv) The circuit and mechanical design of the panel shall be such that
operation of one indicator does not prevent the operation of other
indicators and the alarm is not inhibited by any defect/failure in the
indicator.
xv) Each fire/fault indicator shall be clearly labelled with loop address
from which the call originates.
xvi) Test facility shall be provided to test alarm circuit, sounder indicator
etc.
- Acknowledge button
- Alarm cancel indicator wherever required.
- Isolation/reset facility
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xviii) The control panel shall have electronic/electrical relays for the
following facilities:
- A sounder with distinct audible sound for fire and fault alarm
- Audible signal acknowledge/silence button and LED to indicate
Its operation.
- Voltmeter and ammeter on main D.C. power circuits.
- System 'ON' standby 'ON' indicators, test key/button, operation
indicator and facility to isolate repeater panel/main control panel
from rest of the system.
- Where repeater panel is isolated, its signal shall come on the
main control panel.
- Failure of any indicator circuit shall not prevent the fire alarm
from sounding or acknowledgements/ silencing of alarm from
one loop to another alarm coming from other loop on the panel.
- Switches to actuate alarm from main control panel to repeater
panels.
- Test facility to check fire alarm/fault circuit, indicators etc.
- System healthy
- Alarm
- Pre-alarm
- Fault
- Test
- Alarm silence
- Fault silence
- Processor run
- Processor halt
- Isolate
- Mains 'ON'
- Battery output 'ON'
- Charger 'ON'
- Battery under voltage
- Battery disconnected
- Battery reverse
In case, any of the above failure the panel audible shall be activated
emitting continuous sound. The alarm shall be silenced by accept push
button.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
xx) The control panel shall have facility for the following features :
xxi) It shall have facility of brief user guide menu to enable the operator
for use of various menu functions.
xxiii) The control panel shall be protected from short circuit on the
detector lines and display appropriate message.
xxiv) Control panel shall also monitor open circuits on the detector lines
and display appropriate message.
xxvi) The control panel shall have full fledged built in diagnostics.
xxvii) The control panel having built in battery charger which shall have
facility for float cum trickle charging with boost facility.
The offer shall include all test certificates as required by relevant BIS
and international standards.
i) Application:
Stand post type fire hydrants at DG shed, transformer oil filtration cum
purifier shed, oil storage shed ,pump house and substation building
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
-The stand post type fire hydrant shall be manufactured as per IS:
908(Current).
-The hydrant post may be made of cast iron or MS steel. The minimum
height of post shall be 900 mm.
-The hydrant valve shall have flanged inlet suitable for inlet pipe as per
design and the outlet shall be female type of suitable diameter with
standard threads on it.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
-The flange of the valve need not be provided with holes. Holes will be
made at site to suit the flange of the 'T' joint of the main pipe.
-All the fittings shall be of good quality and workmanship, finish and
free from turns and sharp edges.
-The forgings and castings shall be sound and free from blow hole,
scales and other imperfections. On inspection if any of the defects are
noticed in any one piece, the entire lot may be rejected.
-All M.S. and C.I. parts exposed to water shall be painted with anti-
corrosion paint and outside shall be painted with post office red enamel
paint.
i) Application:
The fire hose boxes/cabinets will be used to store the fire hoses
together with nozzles and will be installed near the hydrant points on
posts. The cabinets are mainly meant for increasing the life of the
hoses by preventing them from exposing to heat, rains and other
atmospheric conditions. These cabinets shall also help in preventing
thefts of hoses and shall be always ready for use in emergency
conditions.
-Fibre glass fire hose cabinet suitable to store two rolls of 15 m long
and hose pipe together with requisite nozzles and hose pipe couplers if
required.
-Brackets and posts to erect the cabinet near the hydrant point.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
-The back wall of the cabinet shall be provided with metal inserts to
provide extra strength for mounting it on the suitable posts/on wall.
-The cabinet shall be fitted with double doors. The doors shall be fitted
with brass hinges, ball type, self-locking arrangement, extra lock facility
and handles. The centre of the door panels shall be fitted with
transparent acrylic sheets.
-The cabinets shall be of light weight and shall be dust and water proof.
Rain guards and dust seals shall be provided at the doors.
-The colour of the cabinet shall be red. `Fire hose cabinet' shall be
written with paint on the glass panel.
iv) Standards:
i) Application:
The fire hoses will be used for supplying large quantities of water at
high pressure in an uninterrupted way from a suitable drain point up to
the place where fire occurs. The hoses will be stored in roll form in
fibre glass hose cabinets. These cabinets will be kept in open
atmosphere wherein temperatures as high as 50 degrees Celsius are
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
Scope of Supply:
Constructional details:
iv) The hose shall have least resistance to flow of water so that
frictional losses are less.
v) It shall have long life and suitable for fighting industrial fires. It
shall not get damaged even after coming in contact with hot
objects or due to the heat radiated from fires that are being
extinguished.
vii) Provision for fitting the gun metal female couplers shall be made
to connect another hose very easily, if required.
x) The hose shall not loose its characteristics even though they are
kept in atmosphere where temperature as high as 50 degrees
Celsius are reached and also relative humidity of 100% are
reached.
Standards:
The hose shall be manufactured as per IS: 8423 current or any other
equivalent International Standards.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
i) Application:
The scope of supply in each set shall include the following items
conforming to the specifications given in the subsequent clauses. The
complete set shall be kept inside the fire hose cabinets for ready use in
case of emergency.
(a) One set of male and female couplings.
(b) One nozzle.
(c) One set of branch pipe
(d) Tools required for the assembly and dismantling of the above
items.
- All fittings shall be of good workmanship, finish and free from burns
And sharp edges.
- The forgings and castings shall be sound and free from blow-holes,
scales, cracks and other imperfections.
- All the castings and forgings shall be made of copper alloy (gun metal).
The specifications of the material shall conform to the relevant Indian
Standards as specified in IS: 903 Current.
- It shall consist of male half coupling, female half coupling and suitable
washers, nuts, bolts, etc.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
- The washer used in the coupling shall conform to Type 'A' of IS:1937
(Current).
- The coupling surface shall be such that the hose can be fitted easily
and will not come out during operation.
v) NOZZLE:
- The nozzle spanner shall be made out of steel of Grade C-35 or C-40
as per IS: 1570(Part 5).
- The shape and size of the spanner shall be as per IS: 903.
- The spanner shall be tested as specified in IS: 903 for testing the
permanent deflection of the spanner job.
v) BRANCH PIPE:
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
- The branch pipe shall have provision at one end for connecting the
female half coupler of the hose and the other end with threads for fitting
the nozzle.
vi) Standards:
All the accessories such as fire hose couplings, branch pipes, nozzles,
nozzle spanners shall be manufactured as per IS: 903(Current).
i) Application:
The portable CO2 type fire extinguisher will be used where fires due to
wood, paper, inflammable liquids, rubbish and fires due to electrical
short circuits are expected.
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Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
-The mouth of the container shall be fitted with stainless steel pipe,
nozzle, valve, PVC hose etc. The valve provided at the mouth shall be
able to control the discharge of fluid as required.
- CO2 shall be charged in gas cartridges which are applied with suitable
material to avoid corrosion.
-The life of the liquid shall be sufficiently long and properties shall not
be changed even though they are kept in temperatures of 50 degrees
centigrade continuously for long periods.
-The container shall be coated with two coats of signal red colour and
enamel paint.
-Every extinguisher shall have instruction plate fitted to it for easy use
at times of emergency.
i) Application:
The dry powder type fire extinguisher will be used where fires due to
wood, paper, inflammable liquids, rubbish and fires due to electrical
short circuits are expected.
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- The mouth of the container shall be fitted with stainless steel pipe,
nozzle, valve and PVC hose. The valve provided at the mouth shall be
able to control the discharge of fluid as required.
- Dry powder shall be charged in gas cartridges which are applied with
suitable material to avoid corrosion.
- The life of the material used shall be sufficiently long and properties
shall not be changed even though they are kept in temperatures of 50
degrees centigrade continuously for long periods.
- The container shall be coated with two coats of signal red colour and
enamel paint.
- Every extinguisher shall have instruction plate fitted to it for easy use
at times of emergency.
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i) Application:
The pipes will be used for supplying water to the post type fire
hydrants, wall mounted hydrants points etc. from the sump to
extinguish the fire through a high pressure pump. The pipes may be
buried underground or supported on saddles on the ground as per
requirements.
-The inside walls of the pipes shall be well finished to reduce the
frictional losses. The pipes shall be free from blow holes.
-The pipe fittings such as bends and 'T' joints shall be made of G.I.
-Radius of the bends and the hole in 'T joints shall be such that there
will not be any obstruction to the flow of water in required quantities.
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i) Application:
These buckets will be used to store sand and will be kept in switching
room, substations, pump house, drive houses, compressor house,
hydraulic power pack room, various floors in silo and sampler house
etc.
i) Application:
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a) The landing valve shall conform to IS: 5290 (current) and shall have
the approval of Tariff Advisory Committee for use in high rise industrial
structures.
b) The landing valve shall be of double ended type with outlets at right
angles to the axis of main pipe.
e) The hydrant valve shall be made of Gun Metal. The wheel shall be
of cast iron.
g) All the fittings shall be of good quality and workmanship, finish and
free from turns and sharp edges.
h) Forgings and castings shall be wound and free from blow holes,
cracks, scales and other imperfections on inspection, if any defect is
noticed in any one piece, the entire lot may be rejected.
j) All M.S. and C.I. parts exposed to water shall be painted with anti-
corrosion paint and out side shall be painted with post office red
enamel paint. Alloy parts shall also be painted with suitable paint.
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i) Application:
The pump motor set shall be used on surface for pumping water for fire
fighting purposes. The pump shall draw water from an underground
sump (1,35,000 litre capacity, minimum) and supply to the nozzles for
spraying the water at fire.
ii) Duty:
The pump motor set shall be able to operate continuously at full load in
ambient temperature upto 50 degrees Celsius, relative humidity up to
100%. The motor and pump shall be suitable for frequent starts and
stops.
iii) Scope:
(f) Any other items which are necessary for efficient operation of
the pump but not covered in this list.
Mechanical:
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d) The pump shall have priming funnel for priming purpose. The
pump shall not get damaged when it is started in partially primed
condition.
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Electric Motor:
-the terminal voltage differing from its rated value by not more
than+/-10% or
-the frequency differing from its rated value by not more than +/-
6% or any combination of above limiting to 10 %
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Starter:
A push button type start / stop switch will be provided in the pump
house for starting and stopping in case emergency. The pump will
receive power from a MCC and controlled from a central control room.
A diesel operated pump shall also be supplied and installed in the
pump room for fire fighting purpose.
The system shall drain a pre- determined quantity of oil from the tank
top through outlet valve to reduce the tank pressure and inject nitrogen
gas at high pressure from the lower side of the tank through inlet
valves to create stirring action and reduce the temperature of top oil
surface below flash point to extinguish the fire. Conservator tank oil
shall also be isolated during bushing bursting, tank explosion and oil
fire to prevent aggravation of fire.
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(iv) Flame sensors - UV/IR spectrum based , for external and early
pre-arc fume fire detection.
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2.5.1.1 Scope:
This specification is intended to cover the complete soil exploration
of the Plant area, as elaborated hereunder and as may be required
in the interest of the work.
Making test bores in the area for soils including taking out requisite
number of undisturbed samples at different depths for Laboratory
tests, making standard penetration tests at different depths,
recording ground water levels, maintaining driving record,
preparation of bore-hole log for each bore-hole etc.
Conducting plate bearing load test including cyclic loading and
unloading operations wherever required.
Laboratory tests on requisite numbers of collected samples for
determining natural moisture content, particle size analysis, index
properties, wet and dry density, unconfined compression test,
shear test by tri-axial compression, consolidation tests, permeability
tests etc and chemical analysis for soil and water samples collected
from bore holes for SO4 & CL.
If rock is encountered, drilling through rock up to 3 m including core
recovery, 90% core recovery is to be obtained and determination of
crushing strength of rock samples.
Direct undisturbed soil sample testing by open trial pit.
Preparation and submission of a comprehensive soil report with
recommendations for type of foundation, bearing capacities for
shallow foundation, method of deep excavation, probable
settlement for foundations etc.
Locations of performing direct load test and open trial pit are to be
selected by the contractor, but before carrying out the tests prior
approval should be taken from the Purchaser regarding the location
of such test.
2.5.1.2 Records:
All field records shall be submitted to the Engineer-in-charge in
duplicate as and when they are recorded during the process of soil
investigation.
2.5.1.3 Test Boring:
Test boring through different layers of soil shall be carried out by
the Contractor at the locations as marked on approved system
drawings and at such other places within the plant areas as
directed by the Engineer-in-charge in a manner described below.
Depth of boring shall be 20 m or refusal strata, whichever is lesser,
below the natural ground level. If the present formation level is
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above the natural ground with filled up soil, the depth of boring
mentioned shall exclude such filled up soil. Various methods of
boring are described in IS code of practice IS 1892 latest revision,
which may be adopted. Shell and auger type boring with boring
diameter not less than 150 mm should preferably be carried out in
such type of soil as found in the site. However, the Contractor shall
describe in detail, the equipment and method of boring he proposes
to use.
Samples of undisturbed soil shall be obtained preferably at every
1.5 m or where a change in strata is indicated but in no case, more
than 3 m and a sample shall be obtained on the average for every
2.0 m depth of boring, since it is intended to ascertain the
characteristics of the soil at various depths. If, however, there are
uniformity in the characteristics of the soil for certain depths, the
Engineer-in-charge may limit the number of samples stipulated
above.
The size of soil test samples specially undisturbed samples shall
preferably conform to the type of sampler used. The contractor
may use either open tube samplers or piston samplers. While
collecting undisturbed samples the boring rods along with the
sampler should be pushed into the soil and in no case the
contractor should resort to hammering. If there is any surface
water on the top of sample, this shall be wiped off with soaking
paper and immediately sealed with wax and marked with respective
test bore numbers, depth at which the sample was taken and other
relevant information.
Ground water level for each bore hole shall be checked during
boring operation and shall be recorded in bore log. The contractor
shall maintain a bore log for each soil test boring on an approved
pro-forma. While carrying out standard penetration test the
contractor shall record the number of blows for each 150 mm of
penetration of the sampling split spoon. The first 15 cm of
penetration shall be considered as seating drive and the total
number of blows for the next 30 cm of penetration resistance at the
specified depth. Hammer used for driving the split spoon shall be
65 kg and a free drop of 750 mm shall be maintained. Records of
driving the sampler, number of blows and penetration shall be
maintained for each bore hole depth-wise. IS 2131 latest edition
should be followed for additional information.
The contractor shall furnish the complete bore log and records of
penetration duly verified and signed by the Engineer-in-charge at
site and submit them in duplicate to the Engineer-in-charge.
2.5.1.4 Direct Load Tests on Soils:
During the exploration the actual locations of the proposed tests
shall be agreed by the Engineer-in-charge. The tests shall be
carried out as described in IS 1888 latest revision "Method of Load
Tests on Soils" unless otherwise specifically directed. The
application of load may be by gravity or by reaction method. The
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Bidder shall furnish in his bid the complete detail of the equipment
and method plate. However, the Contractor shall have to modify
the arrangement at his own cost if it is ultimately found to be
deficient.
The depth of soil for each test shall be 3.0m below ground level.
The excavation and side protection during the test and backfilling
after the test shall be carried out by the Contractor.
While releasing the loads the rebounds should be observed in the
similar manner as that for settlement observations. For load test
point, minimum five cycles of loading and unloading operations to
be done at each loading stage up to the anticipated design value of
yield value whichever reaches earlier. The observations shall be
recorded directly in log books, pro-forma of which has to be
approved by the Engineer-in-charge who shall also be present to
check the data. The Engineer-in-charge shall be notified well in
advance of the detailed programme of the test and shall also be
informed prior to start of releasing the load at each stage so that
the total settlement can be checked by him. The recorded
observations in duplicate shall be handed over to the Engineer-in-
charge.
2.5.1.5 Laboratory Test of Soil Samples:
Adequate number of test samples of soil shall have to be collected
from site and transported carefully to the approved laboratory for
carrying out necessary tests. The laboratory tests shall be carried
out as per standard practice or as decided by the Engineer-in-
charge. The method and procedure of testing to be followed shall
be submitted to the Engineer-in-charge in centuplicate (six copies)
duly signed by the laboratory in-charge.
2.5.1.6 Open Trial Pits:
The location of open trial pits will be decided after placement of
order in consultation with Engineer-in-charge. The excavation of
trial pits shall be up to a depth of 3 m or not below the ground water
table or as directed by the Engineer-in-charge . In no case the
depth shall be extended over 5 m. The size of pits shall be 1m x
1m or as directed by the Engineer-in-charge.
The Contractor shall provide a suitable access to the bottom of the
pit and undisturbed soil samples shall be taken wherever directed.
2.5.1.7 Report on Soil Investigation:
The Contractor shall make analysis of soil and water data as
collected by him in the field and approved by the Engineer-in-
charge as well as field tests and laboratory tests. A comprehensive
report shall have to be prepared by him finally incorporating all the
data collected in proper tabular forms along with specific
recommendations. The report shall be submitted in centuplicate
(six copies) to the Engineer-in-charge for his review and approval.
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2.5.2.1 Scope:
This shall include all works involved in grading, excavation shorting,
filling around foundations and disposal of spoil/soil to a place as
pre-determined or as directed including all leads lifts, etc.
Boring and subsurface data regarding nature of soil, sub-soil water
etc. shown drawings, or otherwise furnished to the Contractor shall
be taken for guidance only, and variation there from shall not affect
the terms of the contract. The Contractor must satisfy himself of the
character and volume of all works under this item and expected
surface, sub-surface and/or sub soil water to be encountered. He
must also satisfy himself about general conditions of site and
ascertain existing and future obstructions likely to come up during
the execution of the Contract to carry out work under this scope.
2.5.2.2 Grading Etc.:
The area to be excavated shall be cleared out of fences, trees,
logs, stumps, bush, vegetation, rubbish, slush etc. and levelled up.
Trees up to 30 cm girth shall be uprooted. Trees above 30 cm
girth, which are to be cut, shall be approved by the Engineer-in-
charge and then marked. Felling of trees shall include taking out
roots up to 60 cm below ground level or 15 cm below formation
level whichever is lower. After the tree is cut roots taken out, the
spot holes formed shall be filled with good earth in 25 cm layers
and consolidated unless directed by the Engineer-in-charge
otherwise. The trees shall be cut in suitable pieces as instructed by
the Engineer-in-charge.
Before earthwork is started, all the spoil and unserviceable
materials and rubbish shall be burned or removed from site to
approved disposal areas as may be specified. Ashes shall be
spread or removed. Useful materials, saleable timber, firewood etc.
shall be the property of the Owner and shall be stacked properly at
the work site in a manner as directed by the Engineer-in-charge.
2.5.2.3 Classification:
All earth work shall be classified under the following categories:
2.5.2.3.1 Ordinary Soil
This shall include all kinds of soil, dry or wet, which can generally
by excavated with spades, except soil containing 50% or more of
kankar, moorum and/or shingle and soft or hard rock.
2.5.2.3.2 Hard Soil
The soil, dry or wet, containing 50% or more of kankar, moorum
and/or shingle or other types of hard soil that usually require use of
pick axes shall be classified under this item. The decision of the
Engineer-in-charge in the matter of classification of this type of soil
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shall be final and binding on the Contractor. This clause shall also
include excavation in consolidated brick ballast and mud concrete.
2.5.2.3.3 Soft and decomposed Rock
This shall include rock, boulders, chalk, slate, laterites and all other
materials which in the opinion of the Engineer-in-charge is rock, but
does not need blasting and could be removed with picks, crow bars
and wedges. The mere fact that the Contractor resorts to blasting
for reasons of his own, shall not mean the rock to be classified as
'hard rock'. This shall also include excavation in macadam and
tarred roads and paths.
2.5.2.3.4 Hard Rock
This shall include rock or boulders, which in the opinion of the
Engineer-in-charge, requires the use of blasting or chiselling for
excavation. This shall include cuttings of the existing structures
coming in the way of excavation.
In case of any dispute regarding classification, the decision of the
Engineer-in-charge shall be final or in case of dispute relevant IS
code shall be followed.
2.5.2.4 Excavation for Foundations and Trenches:
All excavations shall be done to the minimum dimensions as
required for safety and working facility. Prior approval of the
Engineer-in-charge shall be obtained by the Contractor, in each
individual case, for the method he proposes to adopt for the
excavation, including dimensions, side slopes, shoring, de-
watering, disposal etc. This approval however, shall not in any way
make the Engineer-in-charge responsible for any consequent loss
or damage. The excavation must be carried out in the most
expeditious efficient manner.
Prior to starting the excavation, the ground level at the location
shall be checked jointly with the Engineer-in-charge.
The rough excavation may be carried up to a maximum depth of
150 mm above the final level. The balance shall be excavated with
special care. If directed by the Engineer-in-charge soft and
undesirable sports shall be filled up as instructed by the Engineer-
in-charge.
If the excavation is done to a depth greater than that shown on the
drawing, or directed by the Engineer-in-charge, due to Contractor's
fault, the excess depth shall be filled up to the required level with
cement concrete not leaner than 1:4:8 ordinary concrete or richer
as directed by the Engineer-in-charge in each individual case.
2.5.2.5 Protection:
The Engineer-in-charge shall be notified by the Contractor as soon
as the excavation is expected to be completed in 24 hours time so
that it may be inspected by him at the earliest. Immediately after
approval of the Engineer-in-charge, the excavation must be
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2.5.3.1 General:
2.5.3.1.1 Scope
This specification covers general requirements for supply,
fabrication and delivery at site of structural and miscellaneous
steel.
2.5.3.1.2 Steel Materials
Steel materials shall comply with the IS specifications (latest
editions) laid down elsewhere and/or as called for on the approved
design drawings.
Contractor shall furnish to Engineer-in-charge duplicate copies of
all mill orders, (un- priced) covering the material ordered by him for
this project and also the test reports received from the mills for
Engineer-in-charge's check and information.
2.5.3.1.3 Drawings
Engineer-in-charge reserves the right to make correction to
drawings. Revisions to drawings and any new drawings made to
include additional work shall be considered as a part of this
specification and the Owner shall entertain no extra claim on this
account.
Unless otherwise specified, the drawings and specifications are
intended to include everything obviously requisite and necessary
for the proper and entire completion of the work and the job shall
be carried out accordingly for the completeness as required.
In the case of variations in drawings and specification the decisions
of the Engineer-in-charge shall be final. Should Contractor in the
execution of his work, find discrepancies in the information
furnished by Engineer-in-charge, he shall refer such discrepancies
to the Engineer-in-charge before proceeding with such work or
where ever possible point out the discrepancies while submitting
his offer.
2.5.3.2 Fabrication:
2.5.3.2.1 General
All workmanship and finish shall be of the best quality and shall
conform to the best approved method of fabrication. All materials
shall be finished straight and shall be machined true and square
where so specified. All holes and edges shall be free of burrs.
Shearing and chipping shall be neatly and accurately done and all
portions of work exposed to view shall be neatly finished. Material
at the shops shall be kept clean and protected from weather.
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2.5.3.2.2 Connections
Shop connections shall be either by welding; riveting, or high
strength bolts.
All major field connections shall be of high strength bolts, but
standard MS bolts (IS 1363- latest edition) may be used for fixed
connections of light members such as purlins, girts, staircase
stringers and landing beams, unless these bolts are permitted to be
used by Engineer-in-charge for other connection also. However,
site welding for fabrication is permitted.
High tensile bolts shall comply with the requirements of BS 1083
heat treated to quality or its equivalent in latest IS 1367. All
relevant IS Code (latest edition) for bolting and welding shall be
followed.
In all cases where bearing is critical, all members in the assembly
shall bear on the unthreaded length of the bolt. A washer of
adequate thickness may be provided to exclude the threads from
the bearing thickness if a longer grip bolt has to be used for this
purpose.
All members likely to collect rain-water shall have drain holes
provided.
Not more than one shop splice shall be provided to make up the full
length of a member. Splicing near the mid span of any beam
should be avoided. Splicing of joints shall be done after approval of
the Engineer-in-charge.
2.5.3.2.3 Straightening
Rolled material, before being worked, shall be straightened, unless
otherwise required/specified. If straightening or flattening is
necessary, it shall be done by methods that will not injure the
material. Long plates shall be straightened by passing through
angle or levelling rolls and structural shapes by the use of
mechanical or hydraulic bar straightening machine. Heating or
forging shall not be resorted to without the prior approval or
Engineer-in-charge in writing.
2.5.3.2.4 Cutting
Cutting may be by shearing, cropping, sawing or machine flame
cutting. All re-entrant corners shall be shaped notch-free to a
radius of at least 12 mm. Sheared or cropped edges shall be
dressed to a neat workmanlike finish and shall be free from
distortion and burrs.
The machine flame cut edges shall be properly cleaned. Where
machine flame cutting is permitted for high tensile steel, special
care shall be taken to leave sufficient material and all flame
hardened material shall be removed by machining/edge planning.
Hand flame cutting shall be undertaken only if so permitted by
Engineer-in-charge and shall only be carried out by an expert in
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such work. Hand flame cut edges shall be ground smooth and
straight.
Edge planning of sheared, cropped or gas cut edges is not
intended unless the sheared, cropped or gas cut edges are such as
to warrant it or it is specifically required.
2.5.3.2.5 Rolling and Forming
Plates for circular bins, bunkers, hoppers etc. shall be accurately
laid off and rolled or formed to required profile/shape as called for
on the drawings. Adjacent sections shall be match-marked for
facilitating accurate assembly, welding and erection in the field.
2.5.3.2.6 Punching and Drilling
Holes in secondary members such as purlins, girts, lacing bars etc.
may be punched full size through material not over 12 mm thick.
Holes must be cleaned out, without burr or ragged edges. Holes for
all other connections shall be drilled accurately and the burrs
removed effectively. Where several parts are to be drilled, they
shall be first assembled, tightly clamped together and drilled
through.
Sub-punching may be permitted before assembly, provided the
holes are punched 3 mm smaller in diameter than the required size
and reamed after assembly to the full diameter. The thickness of
material punched shall not exceed 16 mm.
Holes for turned and fitted bolts shall be drilled to a slightly smaller
diameter and reamed to a diameter equal to the nominal diameter
of the shank or barrel subject to HB tolerance specified in IS 919
(latest edition).
Where reamed members are taken apart for shipping or handling,
the respective pieces reamed together shall be so marked that they
may be re-assembled in the same position in the final setting up.
No interchange of reamed parts will be permitted. Poor machining,
over drilling and equality in holes shall be cause for rejection.
Burning holes with gas is strictly prohibited.
2.5.3.3 Riveting:
All rivet steel used shall conform to either IS 1148 or IS 1119 (latest
edition) as may be applicable. The parts of riveted members shall
be well planned and firmly drawn together with bolts before riveting
is commenced. The drifting done during assembling shall be only
such as to bring the parts into position and be only such as to bring
the parts into position and shall not be such as to enlarge the holes
or distort the metal. Contact surfaces inaccessible after riveting
shall be painted before assembly prior to riveting. Rivets shall be
heated uniformly to a light cherry red (10850 C) and driven while
not. Rivets when heated and ready for driving shall be free from
slag, scale and carbon deposit. When driven, they shall completely
fill the holes. Rivet heads shall be full, neatly made, concentric with
the rivet holes and in full contact with the surface of the member,
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rigid part of the joint to its free edges. During this operation there
shall be no rotation of the part not turned by the wrench.
Bolts may be installed without hardened washers when tightening
is done by the turn of nut method. However, normal washers shall
be used.
Bolts tightened by the turn-of-nut method may have outer face of
nut match marked with protruding bolt point before final tightening,
thus affording the inspector visual means of noting the actual nut
rotation. Such marks can be made by the wrench operator by
suitable means after the bolts have been brought up snug tight.
ii) Calibrated Wrench Tightening
When calibrated wrenches are used to provide the bolt tensions
specified earlier their setting shall be such as to include a bolt
tension 5% to 10% in excess of this value. These wrenches shall
be calibrated at least once each working day by tightening in a
device capable of indicating actual bolt tension, not less than three
typical bolts of each diameter from the bolts being installed. Power
wrenches shall be adjusted to stall or cut out at the selected
tension. If manual torque wrenches are used, the torque indication
corresponding to the calibrating tension shall be noted and used in
the installation of all bolts of the tested lot. Nuts shall be in
tightening motion when torque is measured. When using calibrated
wrenches to install several bolts in a single joint, the wrench shall
be turned to 'touch up' bolts previously tightened, which may have
been loosened to the prescribed tension. Bolts tightened by means
of a calibrated wrench shall be installed with a hardened washer
under the nut or bolt head, whichever is the element turned in
tightening.
In either of the above two methods, because of bolt entering and
wrench operation clearances, tightening may be done by turning
the bolt while the nut is prevented from rotating.
Impact wrenches, if used, shall be of adequate capacity and
sufficiently supplied with air to perform the required tightening of
each bolt in approximately ten seconds.
2.5.3.5 Welding:
2.5.3.5.1 General
Electrodes for shielded arc manual welds shall comply with the
requirements of IS 814 latest edition and shall be of an approved
make.
The electrodes shall be suitable for use in the position and type of
work as laid down in the above specifications and as recommended
by the manufacturers.
Electrodes flux covering shall be sound and unbroken. Broken or
damaged coating shall, cause the electrodes to be discarded.
Covered electrodes for manual arc welding shall be properly stored
in an oven prior to use in a manner recommended by the
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to sound metal and side welded to fill up the ends to the required
reinforcement.
Each layer of multiple layer weld including root and surface runs
may be moderately peered with light blows from a blunt tool. Care
shall be exercised to prevent scaling or flaking of weld and base
metal from over peering.
No welding shall normally be done on parent material at a
temperature below (-) 50 C. However, if welding is to be
undertaken at low temperatures, adequate precautions as
recommended in relevant Indian Standards shall be taken. When
the parent material is less than 40 mm thick and the temperature is
between (-) 50 C and 00 C, the surface around the joint to a
distance of 100 mm or four times the thickness of the materials,
whichever is greater, shall be preheated till it is hand warm. When
the parent material is more than 40 mm thick, the temperature of
the area mentioned above shall in no case be less than 200 C. All
requirements regarding preheating of the parent material shall be in
accordance with the relevant Indian standard.
Electrodes other than low hydrogen electrodes shall not be
permitted for thickness of 75 mm and above.
Before commencing fabrication of a member or structure in which
welding is likely to result in distortion and/or locked up stresses a
complete programme of fabrication, assembly and welding shall be
made and submitted to Engineer-in-charge for approval. Such a
programme shall include, besides other appropriate details, full
particulars in regard to the following:
i) Proposed preheating in component such as flanges and pre-
setting of joints to offset expected distortion.
ii) Make up of sub-assemblies proposed to be welded before
incorporation on final assembly.
iii) Proposed joint forms, classification of wire and flux or
covered electrodes, welding process including fitting and
welding sequences with directions in which freedom of
movement is to be allowed.
iv) Proposed number, spacing and type of strong backs and
details of jigs fixtures for maintaining proper fit up and
alignment during welding.
v) Any other special features like assembling similar back to
back or stress relief if so desired by Engineer-in-charge.
Welding shall be carried out at contractor's cost to establish
the efficiency of the proposed programme, with any
modification suggested by the Engineer-in-charge, in limiting
distortion or/and residual stress to acceptable levels.
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If mill test reports are not available for any steel materials the same
be got tested by the contractor to Engineer-in-charge's satisfaction
to demonstrate conformity with the relevant specification. The
costs of such tests will be borne by the contractor.
i) Test on Welds
Where root and intermediate passes of weld is examined by
magnetic particle testing such testing shall be carried out
throughout its entire length in accordance with ASTM specification
E-109. In the case of completed welds, such tests shall be carried
out in accordance with ASTM specification E-109 or E-136 as
decided by Engineer-in-charge.
If heat treatment is performed, the completed weld shall be
examined after the heat treatment. All defects shall be repaired
and re-tested. Magnetic particle tests shall be carried out using
alternating current. Direct current may be used with the permission
of Engineer-in-charge.
ii) Liquid Penetrate Inspection
In the case of welds examined by liquid Penetrate Inspection, such
tests shall be carried out in accordance with ASTM C-165 or IS
3658 (latest edition). All defects shown shall be repaired and
rechecked.
iii) Radiographic Inspection
All full strength butt welds shall be fully radio graphed in
accordance with the recommended practice for radiographic testing
as per ASTM -E-93 and part UW-51 of ASMD code Section-VIII.
iv) Dimensions, Workmanship and Cleanliness
The structural steel members shall be inspected at all stages of
fabrication and assembly to verify that dimensions, tolerance,
alignment and surface finish, painting where specified are in
accordance with the requirements shown on contractor's approved
shop drawings.
v) Inspection of Test Failure
In the event of any failure of structural steel members to meet an
inspection or test requirement; Contractor shall notify the Engineer-
in-charge or his authorised representative. Contractor must obtain
permission from the Engineer-in-charge before repair is
undertaken. The quality control procedures to be allowed to ensure
satisfactory repair shall be subject to approval by Engineer-in-
charge.
Engineer-in-charge has a right to specify additional inspection or
testing as he deems necessary, and the additional cost of such
testing will be borne by Contractor. Contractor shall maintain
records of all inspection and testing which shall be made available
to Engineer-in-charge or his authorised representative.
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All field rivets, field welds, and serious abrasions to the shop coat
shall be spot painted with the same paint used for the shop coat
where specified, surfaces which will be in contact after site
assembly shall receive a coat of paint (in addition to any shop
priming and shall be brought together while the paint is still wet.
Where the steel has received a metal coating in the shop, this
coating shall be completed on the site so as to be continuous over
any field welds, field rivets or bolts. Each coat of paint shall have
an optimum thickness. The overall paint thickness should not be
less than 100 microns.
2.5.3.9 Galvanizing:
2.5.3.9.1 General
Structural steel work for switchyard or other structures as may be
specified in the contract shall be hot dip galvanised in accordance
with the American Society for Testing and Materials Specification
ASTM-A 123 or equivalent Indian Standard Specifications. Where
the steel structures are required to be galvanised the field
connection materials like bolts, nuts and washers shall also be
galvanised, sherardized or Electro plated.
2.5.3.9.2 Surface Preparation
All members to be galvanised shall be cleaned, by the process of
picking, of rust, loose scale, dirt, oil, grease, slag and spatter of
welded areas and other foreign substances prior to galvanising.
Pickling shall be carried out by immersing the steel in an acid at a
suitable concentration and temperature. The concentration of the
acid and the temperature of the bath can be varied, provided that
the pickling time is adjusted accordingly.
The pickling process shall be completed by thoroughly rinsing with
water, which should preferably be warm, so as to remove the
residual acid.
2.5.3.9.3 Procedure
Galvanising shall be carried out by hot dip process in a proper and
uniformly heated bath. It shall meet all the requirements when
tested in accordance with IS 2633 (latest edition) - Methods of
testing weight, thickness and uniformity of coating on hot dipped
galvanised articles. The zinc coating shall be uniform, clean and of
a standard thickness on the entire surface of the material
galvanised. The acceptable values of the coating of zinc on the
steel materials shall be in accordance with relevant latest I.S code.
After finishing the threads of bolts, galvanising shall be applied over
the entire surface uniformly. The threads of bolts shall not be
machined after galvanising in order to preserve the integrity of the
zinc coating. Bolts shall preferably be Sherardized or Electro-plated
in order to maintain a better thread.
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The threads of nuts may be tapped after galvanising but care shall
be taken to use oil in the threads of nuts during erection.
The surface preparation for galvanising and the process of
galvanising itself, shall not adversely affect the mechanical
properties of the materials to be galvanised. Where members are of
such lengths as to prevent complete dipping in one operation, great
care shall be taken to prevent warping.
Materials on which galvanising has been damaged shall be acid
stripped and re-galvanised unless otherwise directed, but if any
member becomes damaged after having been dipped twice, shall
be rejected. Special care shall be taken not to injure the skin on
galvanised surfaces during transport handling and erection.
Damages, if occur shall be made good in accordance with the
provisions of this specification or as directed by the Engineer-in-
charges.
2.5.3.10 Applicable Codes and Specifications (All referred codes
should be latest edition):
Unless otherwise specified therein, materials and workmanship
shall conform to the latest editions of the one or as many as
applicable of the following standards or their approved equivalents,
or as applicable, if not included in the list.
IS 808 - Rolled steel beam, Channel and angle sections.
IS 8500- Structural steel- Micro alloy (Medium and High strength
qualities).
IS 2062 Steel for General structure purpose.
IS 1977 - Structural steel (Ordinary quality) Low tensile.
IS 1148 - Hot-rolled rivet-bars (up to 40 mm diameter for structural
purposes.)
IS 1149 High tensile rivet bars for structural purposes.
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2.5.4.1 Scope:
This specification covers general requirements for erection of
structural and miscellaneous steel works.
2.5.4.2 Erection Scheme:
Each bid shall be accompanied by a broad erection scheme
prepared by the Bidder after a thorough study of the bid drawings
and the site conditions. The erection scheme shall describe the
methods proposed to be employed by the Contractor for unloading,
transporting within the site, handling, assembling, hoisting and
erection of the structural and miscellaneous steel components and
the type, capacity and quantity of equipment that the Contractor
proposes to bring to site for all these operations. The scheme shall
also indicate the strength and trade-wise compositions of the work
force and supervisory personnel that will be deployed by the
Contractor for the various operations.
2.5.4.3 Site Operations:
An experienced and qualified superintendent shall be in full time
charge of the job.
The Contractor shall complete the structural foundations and all
preliminary works on site well before the arrival of structural steel,
such as establishment of office, stores, unloading gantry, labour
quarters if any, electrical and water connections, electrical winches,
derricks, cranes, compressors, all tools and tackles, rivet guns,
welding sets, torque wrenches, spud wrenches, staging, etc. as
part of his contract and any other work that may be necessary so
as to start erection immediately after the arrival of first batch of
steel at site.
The Contractor shall furnish at his own expense, the necessary
non-inflammable staging for hoisting materials or equipment
required for the erection work and shall remove and take them
away after completion of the job. The Contractor shall also provide
necessary passageways, offices, safety belts, helmets, lights and
other fittings to the satisfaction of the Owner/Engineer-in-charge
and to meet the rules of local authorities and for protection to his
men and materials. A licensed electrician shall be kept on the job
for full period to maintain the Contractor's electrical equipment and
connections.
The Contractor shall protect all existing plant structures, piping,
conduits, equipment and facilities against damage during erection.
Any damage caused by the Contractor shall be repaired entirely at
the Contractor's cost to the satisfaction of the Owner/Engineer-in-
charge. If work has to be carried out adjacent to existing
switchyards or electrical installations, which are live, the Contractor
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2.5.5.1 Scope:
The work covers all operations connected with excavation in Hard
Rock including all labour and material. The definition of Hard Rock
should be as specified in specification for preparation of site and
earth works in foundation and trenches. The disposal of excavated
material to a designated location is included.
2.5.5.2 General:
Excavation in hard rock shall generally be done by blasting. A valid
blasting licence shall be obtained by the Contractor from authorities
concerned. If the permission for blasting is refused by the
Engineer-in-charge for safety considerations the rock shall be
removed by wedging, picking, barring, burning and sudden
quenching or other approved means. All the excavation beyond
the minimum excavation limits shall be filled back with the same
class and type of material as proposed and approved by the
Engineer-in-charge. While blasting the Contractor shall take all
possible care to preserve rock below and beyond the lines of
excavation in the soundest condition possible.
2.5.5.3 Blasting:
For blasting operations required in case of excavation of rock, the
following points shall be observed:
The Contractor shall employ competent and experienced
supervisor and licensed blaster in-charge of each set of operations
and he will be held personally responsible to ensure that all safety
regulations are followed. Before any blasting is carried out, the
Contractor shall inform the Engineer-in-charge and obtain his
approval in writing for resorting to such operations. He shall
intimate the hours of firing charges, the nature of explosive and
extent to be used and the precaution to be taken for general safety.
The Contractor shall ensure that all workmen and the personnel at
site are excluded from the unsafe area, to be determined by the
Engineer-in-charge, at least 15 minutes before firing by sounding
warning siren. The area shall be encircled by red flags. Within 30
metres from structures no blasting shall be done without prior
approval of the Engineer-in-charge in writing. When blasting is
necessary adjacent to partially or completely built structures the
Contractor shall take all the precautions necessary to prevent flying
rock from causing damage to the structures.
The Contractor shall be responsible for all damage caused by
blasting and shall replace or repair the structures at his own cost.
All major blasting shall be completed prior to starting concrete work
on site.
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successively. If the blasts do not tally with the numbers fired, the
difference indicating the misfired shall be carefully located after half
an hour and when located shall be exploded by drilling a fresh hole
along the misfired hole (but not nearer than 600 mm from it) and by
exploding a new charge.
A wooden tamping rope shall be used to push cartridges home and
metal rod or rammer shall not be permitted on the site of work. The
charge shall be placed firmly into place and not rammed or
pounded. After a hole is filled to the required depth, the balance of
the hole shall be filled with stemming which may consist of sand or
stone dust or similar inert material.
The Contractor shall preferably fire the explosive electrically.
The explosive shall be exploded by means of a primer which shall
be fired by a detonator by a fuse instantaneous detonator (FID) or
other approved cables. The detonators with FID shall be
connected by special nippers.
In dry weather and normal dry excavation, ordinary low explosive
gunpowder may be used. In damp rock, high explosive like
gelatine with detonator and fuse wire may be used. In underwater
or excavation with substantial seepage causing accumulation,
electric detonation shall be necessary.
Holes for charging explosive shall be drilled with pneumatic drills,
the drilling pattern being so planned that rock piles after blasting
will be suitable for handling without secondary blasting.
When excavation almost reaches the level, hand trimming shall
have to be done for dressing the surface to the desired level. Any
extra excavation shall be filled up as instructed by the Engineer-in-
charge, preferably by cement concrete with a mix not leaner than
1:3:6.
The Contractor shall be responsible for any accident to workmen,
public or owners property due to blasting operations in absence of
adequate protection from his end. The Contractor shall also be
responsible for strict observance of rules, laid down by the
Inspector of Explosives, or any other Authority, duly constituted
under the State Government or the Union Government.
2.5.5.3.3 Procurement and Storage of Explosives
The Owner shall obtain for the Contractor necessary licence from
the authorities dealing with explosives, but fees, if any, required for
obtaining such licence shall be borne by the Contractor. The
Contractor shall have to make necessary storage facilities for the
explosives as per rules of local Authorities/Govt. of India.
Explosive shall be kept dry and shall not be exposed to direct rays
of sun or in the vicinity of fire, stoves, steam pipes or heated metal,
etc. No explosive shall be brought near the rock in excess of
quantity required for a particular amount of firing to be done. Any
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surplus left after filling the holes shall be removed at least 400
metres from the firing point.
2.5.5.3.4 Limitations
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2.5.6.1 Scope:
This specification deals with cement concrete, Plain or Reinforced,
for general use, and covers the requirements for concrete
materials, their storage, grading, mix design, strength and quality
requirements, pouring at all levels, reinforcements, protection,
curing, formwork, finishing, painting, admixtures, inserts and other
miscellaneous works.
The provision of the latest revision of IS 456 shall be complied with
unless permitted otherwise and any other Indian standard code
(latest revision) shall form a part of this specification to the extent it
has been referred to or applicable within this specification.
2.5.6.2 Materials:
2.5.6.2.1 Cement
Cement used shall be ordinary Portland cement / Portland slag
cement. Rapid hardening Portland cement can be used under
special circumstances, if permitted by the Engineer-in-charge. Only
fresh cement shall be used.
2.5.6.2.2 Aggregates
All aggregates shall conform to all provisions and test methods of
IS 383 latest revision and/or IS 515 latest revision.
Samples of aggregates proposed to be used shall be submitted
free of charge in sufficient quantities to the Engineer-in-charge with
sieve analysis data for his approval. Approved samples will be
preserved by him for future reference. This approval will not in any
way relieve the Contractor or his responsibility of producing
concrete of specified qualities.
2.5.6.2.3 Coarse Aggregate
Coarse aggregates shall consist of uncoated, hard strong, dense
and durable pieces of crushed stone, and shall be free from
undesirable matters, viz. disintegrated stones, soft, flaky or
elongated particles, salt, alkali, vegetable matter or other
deleterious substances. The amount of different undesirable
substances in coarse aggregates shall not exceed the percentage
limits by weight as specified in relevant IS codes, but in no case,
the total amount of all the undesirable substances shall exceed 5%.
Aggregates other than crushed stone conforming to the provisions
of this specification may be used under special conditions, if
permitted by the Engineer-in-charge. Washing of aggregates by
approved means shall be carried out, if desired by the Engineer-in-
charge.
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At least 4 trial batches are to be made and 7 test cylinders taken for
each batch noting the slump on each mix. These cylinders shall
then be properly cured and two cylinders for each mix shall be
tested in a testing laboratory approved by the Engineer-in-charge at
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i) General
If it is so desired, the Contractor shall prepare, before
commencement of actual work, design and drawings for formwork
and centring and get them approved by the Engineer-in-charge.
The formwork shall conform to the shape, lines and dimensions as
shown on the drawings.
The centring shall be true, rigid and thoroughly braced both
horizontally and diagonally. The forms shall be sufficiently strong
to carry without undue deformation, the dead weight of the concrete
as a liquid as well as working load. Where the concrete is vibrated,
the formwork shall be strong enough to withstand the effects of
vibration without appreciable deflection, building, distortion or
loosening of its components. The joints in the formwork shall be
sufficiently tight to prevent any leakage of mortar. The formwork
shall be such as to ensure a smooth uniform surface free from
honeycombs, air bubbles, bulges, fins and other blemishes. Any
blemish or defect found on the surface of the concrete must be
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-In case of cantilever slabs and beams, the centring shall remain
till structures for counter acting or bearing down have been erected
and have attained sufficient strength.
-Proper precautions should be taken to allow for the decrease in
the rate of hardening that occurs with all types of cement in cold
weather and accordingly stripping time shall be increased.
- Work damaged through premature or careless removal of forms
shall be reconstructed.
The Contractor shall record on the drawing or in other approved
manner, the date of which the concrete as placed in each part of
the work and the date on which the formwork is removed there from
and have this record checked and countersigned by the Engineer-
in-charge. The Contractor shall be responsible for the safe removal
of the formwork, but the Engineer-in-charge may delay the time of
removal if he considers it necessary. Any work showing signs of
damage through premature removal of formwork of loading shall be
entirely re-constructed without any extra cost to the Employer.
Before removing any formwork, the Contractor must notify the
Engineer-in-charge well in advance to enable him to inspect the
concrete, if he so desires.
iv) Tolerance
The formwork shall be so made as to produce a finished concrete
true to shape lines, levels, plumbs and dimensions as shown on the
drawings. The formwork shall be designed and constructed so as to
remain sufficiently rigid during placing &compaction of concrete,
and shall be such as to prevent loss of slurry from the concrete. For
further details regarding design, detailing, etc. reference may be
made to I.S 14687(latest edition). The tolerance on the shapes,
lines & dimensions shown in the drawing shall be within the limits
given below:
a) Deviation from specified dimensions of cross section - 6 mm
of columns & beams +12mm
b) Deviation from dimensions of footings
1) Dimensions in plan -12 mm
+50mm
2) Eccentricity 0.02 times the width of the footing in the
direction of deviation but not more than
50 mm
3) Thickness + 0.05 times the specified thickness.
v) Re-use of forms
Before re-use, all forms shall be thoroughly scraped cleaned, joints,
etc. examined, and when necessary repaired, and in-situ used/re-
used, if declared unfit or unserviceable by the Engineer-in-charge.
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i) Ordinary
This shall be used in places where ordinary surface finish is
required and shall be composed of steel and or approved good
quality seasoned wood.
ii) Plywood
This shall be used on exposed surfaces, where a specially good
finish is required and shall be made mostly of approved brand of
heavy quality plywood to produce a perfectly level, uniform and
smooth surface. Re-use may only be permitted after special
inspection and approval by the Engineer-in-charge. He may also
permit utilisation of used plywood for the 'ordinary' class.
iii) Imperfect Surfaces
a) Interior
Imperfect surfaces, where strength is not the criteria shall be
patched and rubbed smooth with carborundum stone. Immediately
after the formwork is stripped off, fins and projections shall be
removed and the concrete surface affected thereby shall be rubbed
smooth to satisfaction of the Engineer-in-charge.
b) Exterior
Imperfect surfaces shall not be patched, but shall be repaired by
removal and replacement of the member or as directed by the
Engineer-in-charge. Small voids shall be filled with 1:2 cement
mortar pressed into holes and floated smooth. Plastering and steel
towelling of surfaces shall not be allowed except in exceptional
cases as may be directed by the Engineer-in-charge. Fins and
projections shall be treated as above.
2.5.6.4.6 Slip Formed Concrete
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Outline programme;
Proposals for shutters and shutter jacking
Proposals for concrete production;
Proposals for reinforcement supply and fixing;
Proposals for finishing and curing;
Contingency plans for dealing with any breakdown or interruption to
the work in progress.
2.5.6.4.7 Anchor Bolts, Anchors, Openings, Sleeves, Inserts and Other Built-
In-Fixtures
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may demand test certificates for the materials and/or get them
tested.
ii) Bitumen Board
Bitumen impregnated fibreboards of approved manufacture as per
IS 1838 shall be used as fillers for expansion joints. It must be
durable and waterproof. It shall be compressible and possess a
high degree of recovery after compression is released. At the
exposed end, the joint shall be sealed with approved sealing
compound to a depth of 25 mm after application of an approved
primer. The sealing compound and the primer shall be applied as
specified by the manufacturer.
iii) Bitumen compound
The gap for expansion joints shall be thoroughly cleaned and the
bitumen compound laid as per manufacturer's specifications. The
compound to be used shall be of approved manufacturer and shall
conform to the requirements of IS 1834 (latest edition).
iv) Separation Joints
Strong and tough alkathene sheet or equivalent of about 1 mm
thickness as approved by the Engineer-in-charge shall be used. It
shall be fixed by an approved sticker to the cleaned surface of the
already set concrete to cover it fully. Fresh concrete shall be laid
against the sheet, care being taken not to damage the sheet in any
way.
v) Rubber Pad
Hard foundation quality rubber pads of required thickness and
shape shall be put below machine or other foundations where
required as shown on the drawings or as desired by the Engineer-
in-charge. The rubber shall be of best quality of approved
manufacture, durable, capable of absorbing vibration and must be
chemically inert and in contact with moist or dry earth under normal
conditions.
2.5.6.4.9 Pressure Grouting
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minimum width 150 mm. The actual size and shape will have to be
specified in drawings. The material should be of good quality
Polyvinyl chloride highly resistant to tearing, abrasion and
corrosion. The physical properties will generally be as follows:
Specific gravity : 1.3 to 1.35
Shore hardness : 60A to 80A
Tensile strength : 100-150
kg/m2
Minimum safe continuous temperature : 700 C
Ultimate elongation : Not less than 275%
2.5.6.6.2 Admixtures
i) In Plaster
The plaster shall be made of cement, sand and the approved
waterproofing admixture as per manufacturer's specification. The
admixture shall be 'IMHERMO' or equivalent as approved by the
Engineer-in-charge. The concrete surface to be plastered shall be
hacked to form a key to Engineer-in-charge's satisfaction. If
desired by the Engineer-in-charge, the Contractor shall have the
work supervised by the manufacturer's supervisor at no extra cost
to the owner.
ii) In Concrete
The admixture shall be the right variety of Lilax, Silvicon, 'ICICO' or
equivalent water proofing cement additive, which conforms to IS
2645 (latest edition). Water proofing additive shall be as far as
possible free from aggressive chemicals like chloride sulphides,
etc. which can cause corrosion of steel reinforcement in RCC.
iii) Other Admixture in Concrete
The Engineer-in-charge may at his discretion instruct the
Contractor to use any admixture in the concrete.
2.5.6.6.3 Surface Treatments
i) Bituminous Coating
Surface to be waterproofed shall be absolutely dry, clean and dust
free. The surface shall be completely coated with hot coal tar pitch
as per IS 216 (latest edition) (not heated above 3750 F) using not
less than 2 kg/m2 or with hot asphalt i.e. bitumen according to IS 73
(latest edition) (not heated above 4000 F) using not less than
1.5 kg/m2. When the first coat has completely dried up and passed
by the Engineer-in-charge, the second coat shall be applied in the
same manner using not less than 1.25 kg/m2 in case of coal tar and
1 kg/m2 in case of asphalt. Immediately after application of the
second coat and before it is dried up, sand requires to be spread
on the surface to cover it completely. Sufficient time shall be
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concrete reinforcement.
I.S 2751 - Code of practice for welding of mild steel plain and
deformed bars for reinforced concrete construction.
I.S 2911 - Code of practice for design and construction of pile
foundation.
I.S 3067 - Code of practice of general design details and
preparatory work for damp proofing and water proofing of
building.
I.S 3370 - (Part-I & II)-Code of practice for concrete structure for the
storage of liquids.
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2.5.7.1 Scope:
This specification covers the construction of brick masonry in
foundations, arches, walls, etc, at all elevations. Only masonry with
first class burnt clay brick is dealt with in this section.
The provision of the latest revision of IS 2212(latest edition) shall
be complied with unless permitted otherwise and any other IS
Codes (latest revision) shall form a part of this specification to the
extent it has been referred to or applicable with this specification.
2.5.7.2 Materials:
2.5.7.2.1 Bricks
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Clay fly ash bricks conforming to I.S 13757 (Latest edition) shall be
sound, compact & uniform in shape & colour. Bricks shall have
smooth rectangular faces with sharp & square corners. The bricks
shall be free from visible cracks, flaws, warpage, nodules of free
lime and organic matter. The bricks shall be hand or machine
moulded. The bricks shall have frog of 100 mm in length 40 mm
width and 10 to 20 mm deep on one of its flat sides. If made by
extrusion process may not be provided with frogs. Fly ash should
conform to grade 1 or grade 2 of I.S 3812 (Latest edition).
Calcium Silicate bricks conforming to I.S 4139 (Latest edition) shall
be sound, compact and uniform in shape. The bricks shall be free
from visible cracks, warpage, organic matter, large pebbles and
modules of free lime Bricks shall be solid and with or without frog.
The bricks shall be made of finely grounded sand siliceous rock &
lime. In addition limited quantity of fly ash conforming to I.S 3812
(latest edition) may be used in the mix.
Bricks shall be of the local standard size. Any other similar size
may be accepted, but no dimension shall vary more than 3mm from
the accepted size.
All bricks which absorb water more than 30% of their own dry
weight after being immersed in water for 24 hours shall be rejected.
All bricks shall have to be approved by the Engineer-in-charge.
Any lot of bricks found not up to the specification, must be removed
from the site immediately at the Contractor's own cost.
Representative samples of bricks to be used shall be submitted to
the Engineer-in-charge and his approval taken before bulk
purchase.
The samples shall be kept sealed with the Engineer-in-charge for
future reference and comparison. All bricks supplied shall conform
to these approved samples in all respects.
Bricks shall be carefully and systematically stacked at locations as
directed in an approved manner. Each stack shall contain equal
numbers of bricks preferably not more than 3,000.
2.5.7.2.2 Water
Water shall be clean and free from deleterious matter such as oil,
acid, alkali, salt and vegetable growth.
2.5.7.2.3 Cement
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Bricks shall be soaked in water before use for at least six (6) hours.
The Contractor shall provide tanks of sufficient capacity to allow the
specified immersion. Bricks shall be laid in water by hand and not
thrown. The bricks shall not be too wet at the time of use, as they
are likely to slip on the mortar bed and there will be difficulty in
ensuring plumb ness of the wall.
Bricks shall be laid with a shore joint in full mortar beds and
thoroughly flushed up with mortar at every course. Face bricks
shall be laid on full, mortar beds and have all vertical joints
completely filled with mortar. All brickwork shall be plumb, square
and true to dimensions shown on drawings and in approved bond.
All brickwork shall be built tightly against columns, floor slabs or
other structural parts, around window and door frames with proper
distance to permit caulked joint. Where drawings indicate that
structural steel columns and beams are to be partly or wholly
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covered with brickwork, the bricks shall be built closely against all
flanges and webs with all spaces between the steel and the
brickwork filled solid with setting mortar with not less than 10 mm in
thickness.
Bricks shall be laid in joints not more than 12 mm thick. Where
stucco finish is specified, the joints of brickwork shall be raked to a
minimum depth of 10 mm to ensure good bond of stucco with
brickwork.
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the header course only. One header for each hole shall be left out.
Such holes, however, shall not be allowed in pillars less than one
metre in width, or immediately neat the skew backs of arches. The
holes left in masonry work for supporting the scaffolding shall be
immediately filled and made good before plastering.
2.5.7.8 I.S Codes (All referred codes should be latest edition):
Important Relevant Codes for this section:
I.S 383 Specification for coarse and fine aggregate.
I.S 1077 - Specifications for common burnt clay building bricks.
I.S 2212 - Code of practice for Brickwork.
2.5.8.1 Code:
This specification covers repairing, finishing, curing, testing,
protection, maintenance till handing over of finishing items for
masonry and concrete.
Before commencing finishing items the Contractor shall obtain the
approval of the Engineer-in-charge regarding the scheduling of
work to minimise damage by other trades. He shall also undertake
normal precaution to prevent damage or disfiguration to work of
other trades or other installations.
2.5.8.2 Preparation of Surface:
All joints in masonry walls shall be raked out to a depth of at least
10 mm with a hooked tool made for the purposes while the mortar
is still green. Walls shall be brushed down with stiff wire brush to
remove all loose dust from joints and thoroughly washed with
water. All laitance shall be removed from concrete to be plastered.
For all types of flooring, skirting, and dado work, the base cement
concrete slab or masonry surface shall be roughened by chipping
and cleaned of all dirt, grease or loose particles by hard brush and
water. The surface shall be thoroughly moist to prevent absorption
of water from the base course. Any excess of water shall be
mopped up.
At any point, the level of base shall be lower than the theoretical
finished floor level by the thickness of floor finish. Any chipping or
filling to be done to bring the base to the required level shall be
brought to the notice of the Engineer-in-charge and his approval
shall be taken regarding the method and extent of rectification work
required.
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2.5.8.3.3 Finish
Generally, the standard finish shall be used unless otherwise
shown on drawing or directed by the Engineer-in-charge.
Wherever any special treatment to the plastered surface is
indicated, the work shall be done exactly as shown on the
drawings, to the entire satisfaction of the Engineer-in-charge
regarding the texture, colour and finish.
a) Standard Finish
Wherever punning is indicated, the interior plaster shall be
finished rough. Otherwise, the interior plaster shall generally
be finished to a smooth surface. The exterior surface shall
generally be finished with a wooden float.
b) Neat Cement Finish
Immediately after achieving a true plastered surface with the
help of a wooden straight edge, the entire area shall be
uniformly treated with a paste of neat cement at the rate of 1
kg/m2 and rubbed smooth with a trowel.
c) Coloured Plaster Finish
This shall be done in the same way as specified in clause (b)
using coloured cement in place of ordinary cement. When
coloured plastering is specified in more than one coat, the
top coat only shall be made with coloured cement.
Coloured cement shall be either ready mixed material or
may be obtained by mixing pigments and cement at site, as
approved by the Engineer-in-charge. The pigments to be
mixed with cement shall conform to appendix A of IS 2114
latest edition. Samples of colouring material shall be
submitted conform in all respects to the approved samples,
which shall remain with the Engineer-in-charge. All coloured
cement and or pigments shall be stored in an approved
manner in order to prevent deterioration.
d) Pebble Dash Finish
Mortar of required thickness consisting of 1 part cement and
4 parts sand by volume shall be applied in the usual manner
as described under plastering clause. While the mortar is
still plastic small pebbles or crushed stone of size generally
from 10 mm to 20 mm as approved by the Engineer-in-
charge shall be thrown on the plastered surface. The
aggregate shall be lightly tapped into the mortar with a wood
float or the flat end of a trowel, in order to ensure satisfactory
bond between the dashing and the mortar.
e) Rough-Cast Finish
A wet plastic mix of 3 parts coloured cement 6 parts sand
and 4 parts aggregate by volume (gravel or crushed stone of
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Where mild steel clamps, stays etc. are used for anchorage, they
shall be galvanised (weight of zinc coating shall not be less than
700 g/m2 of surface) to prevent rust stains developing on the
finished surface. There shall be at least 12 mm gap between the
stone and masonry, which shall be filled up and packed by a mortar
of 1 part cement and 2 parts of sand by volume. After the mortar is
set and cured for at least four days, the exposed surface shall be
neat, of uniform texture and acceptable to the Engineer-in-charge.
Where pointing is specified on drawings it shall be done by mortar
as specified on drawings and/or schedule of items.
2.5.8.4 Acceptance Criteria:
Finish to masonry and concrete shall fully comply with the
drawings, specifications, approved samples and instructions of the
Engineer-in-charge with respect to lines, levels, thickness colour,
texture, pattern and any other special criteria as mentioned in the
body of the specification or as shown on drawings.
2.5.8.5 I.S Codes (All referred codes should be latest edition):
Important relevant code for this section:
I.S 1661 - Code of practice for cement and cement lime plaster
finish on walls and ceilings.
I.S 4101 - Code of practice for external facings and veneers.
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2.5.9.1 Scope:
This specification covers the supply and laying of RCC Hume Pipes
as may be required. The entire work shall be carried out as per
latest editions of Indian Standards I.S 458(latest edition) and I.S
783(latest edition).
2.5.9.2 Supply of Pipes:
The Contractor shall supply the RCC Hume Pipes of various
diameters along with complete fittings required for carrying out the
work. RCC Hume pipes should conform to class NP 3 or NP 2 of
I.S 458(latest edition), as may be required and should be in good
condition. The Contractor must furnish on being demanded by the
Engineer-in-charge, manufacturer's certificates and/or test.
2.5.9.3 Alignment, Levels and Grade:
The work shall be carried out in conformance to the alignments,
levels and grades specified in the drawings. The layout and levels
should be made by him at his own cost from one reference grid and
bench mark given by the Engineer-in-charge. He shall give all help
in instruments, materials and men to the Engineer-in-charge for
checking the detailed layout and levels as and when required.
Making of reference layout and level pillars along the pipeline route
and maintaining them up to completion of the work shall be the
responsibility of the Contractor.
No extra payment shall be made for these.
2.5.9.4 Laying Of Pipes:
2.5.9.4.1 General
The laying of RCC pipes shall conform to clause 9 of IS 783(latest
edition).
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b) Trench condition
In this condition the pipes shall be laid generally on 'First class
Bedding' as per clause 4.2.3 of IS 783(latest edition), unless
directed otherwise.
d) Open condition
In open condition the pipeline shall be supported over rigid
pedestals constructed at intervals not greater than the length of one
individual piece of pipe, as per drawings and instructions of the
Engineer-in-charge. In no case shall joint between two pipes shall
lie at centre of the span between two supports, the pedestals shall
be of rubble masonry or brick masonry or plain/reinforced concrete
with a properly shaped out top to receive the pipe.
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2.5.10.1 Scope:
This specification covers painting, white washing, polishing, etc. of
both interior and exterior surfaces of masonry, concrete, plastering,
plaster of Paris, false ceiling, structural and other miscellaneous
steel items, rain water down comer, floor and roof drains, soil waste
and service water pipes and other ferrous as well as non-ferrous
metal items as shown on drawings or as directed by the Engineer-
in-charge.
If surface to be finished cannot be put in suitable condition for
painting by customary preparatory methods, the Contractor shall
notify the Engineer-in-charge in writing or assume responsibility for
and rectify any unsatisfactory finishing that results.
Before commencing painting, the Contractor shall obtain the
approval of the Engineer-in-charge in writing regarding the
scheduling of work to minimise damage disfiguration or staining by
other trades. He shall also undertake normal precautions to
prevent damage, disfiguration or staining to work of other trades of
other installations.
2.5.10.2 Materials:
Materials shall be highest grade products of well-known approved
manufacturer and shall be delivered to the site in original sealed
container, bearing brand name, manufacturer's name and colour
shade, with labels intact and seals unbroken. All materials shall be
subject to inspection, approved by the Engineer-in-charge. It is
desired that materials of one manufacturer only shall be used as far
as possible and paint of one shade be obtained from the same
manufacturing batch. All paints shall be subjected to analysis from
random samples taken at site from painters bucket, if so desired by
the Engineer-in-charge.
All prime coats shall be compatible to the material of the surface to
be finished as well as to the finishing coats to be applied.
All unspecified materials such as shellac, turpentine or linseed oil
shall be of the highest quality available and shall conform to the
latest I.S standard. All such materials shall be made by reputable
recognised manufacturers and shall be approved by the Engineer-
in-charge.
All colours shall be per painting schedule and tinting and matching
shall be done to the satisfaction of the Engineer-in-charge. In such
cases, where samples are required, they shall be executed in
advance with the specified materials for the approval of the
Engineer-in-charge.
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from the original surfaces, the resurfaced area shall be treated with
minimum one coat of cement primer which should be continued to
the surrounding area from a distance of minimum 100 mm.
Surface with mildew or efflorescence shall be treated as below:
2.5.10.4.2 Mildew
All mildew surfaces shall be treated with an approved fungicide
such as ammonical wash consisting of 7 gm. of copper carbonate
dissolved in 80 ml liqueur ammonia and diluted to 1 litre with water,
or 2.5 % magnesium silica fluoride solution and allowed to dry
thoroughly before paint is applied.
2.5.10.4.3 Efflorescence
All efflorescence shall be removed by scrubbing effected surfaces
with a solution of muriatic acid in water (1:6 to 1:8), and washed
fully with clear and allowed to dry thoroughly.
2.5.10.4.4 Metal
All metal surfaces shall be absolutely clean, dry and free from wax,
grease or dried soap films. All steel and iron surfaces in addition
shall be free from rust. All galvanised iron surfaces shall be pre-
treated with a compatible primer according to the manufacturer's
direction. Any abrasion in shop coat shall be touched up with the
same quality of paint as the original coat.
2.5.10.5 Application:
2.5.10.5.1 General
The method of application shall be as recommended by the
manufacturer. In case of selection of special shades and colour
(not available in standard shades) the Contractor shall mix different
shades and prepare test panels of minimum size 1 metre square as
per instruction of the Engineer-in-charge and obtain his approval
prior to application of finishing paints. Proper tools and implements
shall be used. Scaffoldings if used shall be independent of the
surface to be painted to avoid shade differences of the freshly
repaired anchor holes.
Painting shall be done by skilled labour in a workmanlike manner.
All materials shall be evenly applied so as to be free of sags, runs,
crawls or other defects. All coats shall be of proper consistency. In
case of application by brush no brush marks shall be visible. The
brushes shall be clean and in good condition before application of
paint.
All priming undercoats for painting shall be applied by brush only.
Rollers, spray equipment etc, shall not be used.
No work shall be done under conditions that are unsuitable for
production of desired results. No painting shall be done when
plastering is in progress or is drying. Application of paint which
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seals the surface to moisture shall only be done after the moisture
on and below the surface has dried out.
All coats shall be thoroughly dry before being sand papered or
before the succeeding coat is applied. Coats of paint as specified
are intended to cover surfaces perfectly. In case the surface is not
covered properly by applying the specifying number of coats,
further coats shall be applied by the Contractor when so directed by
the Engineer-in-charge.
All primers and undercoats shall be tinted to approximate the colour
of the finishing coat. Finished coats shall be of exact colour and
shade as per approved samples and all finish shall be uniform in
colour and texture. All parts of mouldings and ornaments shall be
left clean and true to finish.
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2.5.11.1 Scope:
This section covers the layout and construction of drains for pour
water, surface water and sewage together with all fittings and
fixtures and inclusive of ancillary works related to drainage and
sanitary works for the whole plant.
2.5.11.2 Design Requirements:
2.5.11.2.1 General
All pipelines, location of fittings and fixtures etc. shall be as per
drawings or as directed by the Engineer-in-charge. Correctness of
lines, plumb, orientation, symmetry and levels shall be strictly
ensured. All items shall be fully secured against movement in any
direction and selected as to allow easy maintenance where desired
by the Engineer-in-charge. Suitable workers are to be provided for
underground and concealed pipelines and other items.
All pipelines and fittings, fixtures shall be installed leak proof. When
the work under scope of this specification connected with others
the connection shall be such as to prevent any splashing or spilling
or emission of foul odour and gases.
2.5.11.2.2 Rainwater down Comers
Rainwater down comers shall be standard cast iron pipes.
Rainwater down comers shall run along and be secured to walls,
columns etc. Where desired by the Engineer-in-charge these may
have to be installed in chases cut in the structure. All pipes shall
be well secured and supported by adequately strong brackets. The
brackets may be wrought iron clevis type, split ring type or
perforated strap iron type as approved by the Engineer-in-charge.
For vertical runs each pipe shall hang freely on it bracket fixed just
below the socket. Suitable space blocks shall be provided against
the vertical surface to which the pipe is fixed.
All bends and junctions shall be supplied with watertight cleanouts.
Roof and floor drains and yard gullies shall be installed if required,
but where cutting into the structure is necessary it must be grouted
with M-20 cement concrete. All gutters shall be provided with
removable gratings.
All horizontal pipes shall have a minimum fall of 1 in 100.
2.5.11.2.3 Gutters
The gutters shall be made of GI or AC. All gutters shall be supplied
by reputable specialised firms. Each section shall be sufficiently
rigid, edges and corners straight and the slopes perfectly uniform.
The GI Gutters shall have the edges strengthened by suitable
means.
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concrete, the floors shall be left slightly high and carefully bottomed
up as pipe laying proceeds so that the pipe barrels rest on
undisturbed ground. If anywhere the excavation has been carried
too low the packing shall be done in concrete. Where laid on rock
or very hard ground that cannot be easily excavated to a smooth
surface, the pipes shall be laid on a cradle of fine concrete floor or
floor of gravel and crushed stone bed only as desired by the
Engineer-in-charge so as to install even bearing. PVC or similar
pipes shall be laid directly on stable soil and packed with selected
soil.
The minimum support and protection for glazed stone water pipes
shall be as follows:
a) When cover is less than 1 metre below ground level and
where pipes are unavoidably exposed above ground
surface, the pipes shall be completely encased or
surrounded with concrete.
b) Where the pipes are laid on a soft soil with the maximum
water table lying at the invert of the pipe, the pipe sewer
shall be bedded on concrete.
c) Where the pipes have to be laid on a soft soil with the
maximum water table rising above the invert of the pipe, but
below the top of the barrel, the pipe sewer shall be
haunched.
d) Where the maximum water table is likely to rise above the
top of the barrel or wherever the pipe is laid on soft soil the
pipe sewers shall be completely encased or surrounded with
concrete.
Vitrified clay pipes shall be laid on a bed of 150 mm thick
cement concrete (1:3:6 nominal mix by volume).
Cast iron pipes and concrete pipes may be supported on
suitable concrete or brick support, where specified. The
supports shall be unyielding and strong enough. At least
one support shall be located close to each joint. Spacing of
intermediate supports shall be as directed by the Engineer-
in-charge. Pipes shall be secured to the supports by
approved means.
Anchoring of pipes where necessary shall be achieved by
suitable concrete encasing designed for the specified thrust.
2.5.11.3.3 Entry into Structures
For entry of the pipe lines into the building suitable conduits under
the structure or sleeves shall be used. The conduits and sleeves
shall be such as to allow easy repairs and replacement of the
pipes. When openings or chases are required to be made in the
structure for entry of pipelines, locations and sizes shall be marked
by the Engineer-in-charge. After laying of the pipeline the openings
and chases shall be mentioned.
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2.5.11.3.4 Ducts
Where soil, waste and ventilating pipes are accommodated in
ducts, access to cleaning eyes shall be provided. Connection, to
drain shall be through a gully with sealed cover to guard against
ingress of sewer gas, vermin or backflow.
2.5.11.3.5 Traps and Ventilating Pipes
Pipes for carrying off the waste from water closets and waste water
and over flow water from baths, wash basins, sinks to drains shall
be trapped immediately beneath such fixtures. Traps shall have
minimum water seal of 50 mm and shall be ventilated wherever
such ventilation is necessary to maintain water seal of the trap.
Ventilating pipes shall be carried up vertically from the drain to a
height of at least 600 mm above the outer covering of the roof of
the building or as shown on drawings. All vertical ventilating, anti-
siphonage and similar pipe shall be covered on top with a cowl.
The cowl shall be made of CI unless desired otherwise by the
Engineer-in-charge.
2.5.11.3.6 Manholes and Inspection Chambers
The maximum distance between manholes shall be 30 metre
unless specially permitted otherwise. In addition, at every change
of alignment gradient or diameter there shall be a manhole or
inspection chamber. Manhole shall be constructed so as to be
watertight under test. The benching at the sides shall be carried
out in such a manner as to provide no lodgement for any splashing
in case of accidental flooding of the chamber. The channel or drain
at the bottom of chamber shall be plastered with 1:2 (cement, sand
mortar) and finished smooth to the grade. The channels and drains
shall be shaped and laid to provide smooth flow. Connection to
existing sewer lines shall be through a manhole.
Manholes shall be provided with standard covers, usually cast iron
or as desired by the Engineer-in-charge. The covers shall be close
fittings so as to prevent gases coming out.
2.5.11.3.7 Cutting of Pipes
Manufacturer's instruction shall be followed for cutting of pipes
where necessary. Suitable and approved tools shall be used for
the cutting so as to leave clean and square surface to the exit of
the pipe.
2.5.11.3.8 Jointing
Jointing of laid pipes shall be so planned as to avoid completely
any movement or strain to the joints already made. If any joint is
suspected to be damaged it shall be opened out and redone.
All joints between pipes, and fittings and manholes shall be gas-
tight when above ground and watertight when underground.
Method of jointing shall be as per instruction of the pipe and fittings
manufacturer and as approved by the Engineer-in-charge.
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2.5.11.5.4 Sink
It shall be made of glazed stoneware. It shall be wall hung by
painted cast iron brackets and complete with one brass faucets
with nylon washers, chain waste, waste washers, lead pipe with
traps perforated waste with necessary fittings. All fittings including
faucets shall be chromium plated.
2.5.11.5.5 Bathroom Mirror
It shall be made of the best quality 6mm thick indigenous glass and
produced by a reputable mirror manufacturer. It shall be wall
mounted with adjustable revolving brackets. The brackets, screws
and other fittings shall be chromium plated.
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at the highest point of the section under test. The tolerance figure
of two litres per centimetre of diameter per kilometre may be
allowed during a period of 10 (ten) minutes. The test shall be
carried out by suitably plugging the low end of the drain and the
ends of connections, if any, and filling the system with water. A
knuckle bend shall be temporarily jointed in at the top end and a
sufficient length of the vertical pipe jointed to it so as to provide the
required test head. The top end may be plugged with a connection
to a hose ending in a funnel which could be raised or lowered till
the required head is obtained and fixed suitably for observation.
Subsidence of test water may be due to one or more of the
following causes:
i) Absorption by pipes and joints
ii) Sweating of pipes or joints
iii) Leakage at Joints or from Defective Pipes
iv) Trapped Air
Allowance shall be made for by addition of water until absorption
has ceased and after which the test proper should commence. Any
leakage and the defective part of the work shall be cut out and
made good.
a) For Cast Iron Pipes
Cast iron sewers and drains shall be tested as for glazed ware and
concrete pipes. The drain plug shall be suitably structured to
prevent their being forced out of the pipe during the test.
iii) For Straightness
a) By inserting at the high end of the sewer or drain a smooth ball of a
diameter 13 mm less than the pipe bore. In the absence of
obstruction, such as yarn or mortar projecting through the joints,
the ball will roll down the invert of the pipe and emerge at the lower
end; and
b) By means of a mirror at one end of the line and a lamp at the other
end. If the pipe is straight, the full circle of light may be observed,
the mirror will also indicate obstruction in the barrel if the pipe line
is not straight.
2.5.11.7.3 Testing Septic Tank
The septic tank shall be tested for water tightness. It shall be filled
up with water and allowed to stand for 24 hours. Then, it shall be
topped up and allowed to stand again for 24 hours and loss of level
recorded. The fall shall not be more than 15mm.
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2.5.12.1 Scope:
This specification covers all work required for cutting, filling,
compacting, levelling and dressing, box cutting, soiling, edging etc.
required for the construction of R.C.C roads, RCC drains, pipe
culverts etc.
2.5.12.2 General:
2.5.12.2.1 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless otherwise
specified, shall include but not be limited to the following:
i) Furnishing all labour, supervision, services, materials,
scaffolds, earthmoving equipment, tools and plants,
transportation, water supply, necessary approaches etc.
required for the work.
ii) Submit to the Engineer-in-charge progressively, the results of
tests undertaken to assess the degree of compaction in the
backfilling if required by the Engineer-in-charge.
2.5.12.2.2 Information on Site Conditions
The Contractor must satisfy regarding the character and volume of
all work under this item and expected surface, sub-surface and/or
sub-soil water to be encountered. He must also satisfy himself
about general conditions of site and ascertain the existing and
future obstruction likely to come up during the execution of the
Contract to carry out the work under this scope.
2.5.12.2.3 Codes and Standards
All work under this specification, unless specified otherwise, shall
conform to the latest revision of Indian Standard specifications and
codes of practice relevant to the work under the scope of this
specification. For road works and concrete pavement for vehicular
movement, MORT&H specification is to be strictly followed.
If any particular aspect of work is not covered specifically by I.S
Codes (latest edition) or this specification, any other standard
practice as may be specified by the Engineer-in-charge shall be
followed.
2.5.12.2.4 Conformity with Design
Contractor shall carry out the work only as per the approved
drawings prepared by him based on the design drawings issued to
him from time to time or the detailed drawings issued to him and/or
as directed by the Engineer-in-charge.
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2.5.12.2.5 Classification
Classification as indicated in specification, Preparation of site and
Earthwork in foundations and Trenches given in this document
shall be used.
2.5.12.2.6 Materials to be used
All materials required to carry out the work under the scope of this
contract to the satisfaction of the Engineer-in-charge shall be of
best quality and shall be supplied by the Contractor.
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2.5.12.13 Laying:
The metal shall be laid to camber and profile in such a way that the
total thickness of loose metal over stone soling is not less than 150
mm but more shall be used, if required to make the consolidated
thickness at least 100 mm after rolling. While spreading the metal,
proper profile and camber shall be maintained and checked with
templates at every 6 to 7 metres.
No rolling shall be done until laying has been approved by the
Engineer-in-charge.
2.5.12.14 Rolling:
2.5.12.14.1 Dry Rolling
After metals have been laid and dressed as above, metal shall be
rolled dry with a Road Roller of 8 tons minimum weight until well
compacted and there is no appreciable movement of the stone or
wave in front of the advancing roller is noticed and no lines of roller
are left on the surface. Excessive dry rolling should also be
avoided.
When the desired degree of compaction has been obtained by dry
rolling, screening of approved chipping 12 mm down in size should
be spread uniformly over the surface by brooming and this should
be pushed into the interstices by rolling, successive layers of
screening being added till no more chippings are being taken up by
the surface. Any unevenness observed shall be rectified by
removing stones up to a depth of 50cm to 75cm, refilling the same,
hand packing and re-rolling. No watering should be done till this
process is complete. The amount of screening used should not be
less than 1 m3 per 100 m2 of road surface (3 1/2 ft3 per 100 ft2).
Rolling operation has to be very carefully carried out.
Rolling should be done commencing from the edges of the road
and working towards the centre. Roller should be passed equal
and sufficient number of times on the metal spread at every stage
so as to secure equal and thorough compaction. Speed of roller
has to be very slow and uniform and reversing shall be quick and
free from jerks. As far as possible, the reversing process should be
at different sections of the length rolled during each successive trip.
2.5.12.14.2 Wet Rolling (Water Bound Macadam)
When the dry rolling has been completed to the satisfaction of the
Engineer-in-charge the surface is to be watered and kept saturated
and rolled a few turns as specified above. Approved quality binder
(moorum) shall then be spread uniformly over the surface to a
thickness of 20 mm to 12 mm. The roller wheels as well as the
road surface should be constantly watered during wet rolling
process. The rolling should be continued until slurry is formed over
the entire surface and the same moves in the form of a wave in
front of the roller when the rolling operation may end and the
surface is allowed to dry. The finished metalling shall be minimum
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ii) Laying
Laying of concrete pipes shall correspond to I.S 783-Latest edition
and to specification given below:
a) The excavation for laying pipes and foundations of drop wall
should be made as shown on drawings. Side slopes of
excavation shall be the vertical to half horizontal. Half metre
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2.5.13.1 Scope:
This specification covers furnishing, installation, finishing, curing,
testing, protecting, maintenance till handing over the various types
of floor finishes and allied items of work as listed below:
2.5.13.1.1 In situ finishes:
i. Integral finish to concrete base
ii. Red oxide of iron finish
iii. Terrazzo finish
iv. Granolithic finish
v. Patent stone
vi. Metallic hardware like 'Ironite finish
vii. Mastic asphalt finish
viii. Chemical resistant finish
2.5.13.1.2 Tile finishes:
i. Terrazzo tile
ii. Chequered tile
iii. Glazed tile
iv. Tesserae (mosaic, etc.)
v. Chemical resistant
vi. Rubber, vinyl, etc.
vii. Stone slab.
2.5.13.1.3 Base
The base to receive the finish is covered under other relevant
specification.
2.5.13.1.4 Sequence
Commencement, scheduling and sequence of the finishing works
shall be planned in detail and must be specifically approved by the
Engineer-in-charge keeping in view the activities of other agencies
working in the area. However, the Contractor for the finishing items
shall remain fully responsible for all the normal precautions and
vigilance to prevent any damage whatsoever till handing over.
2.5.13.2 Installation:
2.5.13.2.1 Special Materials
Special materials required for individual finishing items are
specified under respective items. In general, all such materials shall
be as per relevant IS codes (latest editions) where available. In all
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The surface shall be kept in shade for 24 hours and then cured for
at least 7 days continuously by flooding with water. The surface
shall not be subjected to any load or abrasion till 21 days after
laying.
If required by the Engineer-in-charge the surface, while still 'green'
shall be indented by pressing strings. The markings shall be of
even depth, in straight lines and the panels shall be of uniform and
symmetrical patterns.
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b) Topping:
The mix for the topping shall be composed of cement, colour
pigment; marble dust and marble chips, proportions of the
ingredients shall be such as to produce the terrazzo of colour
texture and pattern approved by the Engineer-in-charge. The
cement shall be white or grey or a mixture of the two to which
pigment shall be added to achieve the desired colour. To 3
parts of this mixture, 1 part marble powder by volume shall be
added and thoroughly mixed dry. To 1 part of this mix, 1 to 1
1/2 parts of marble chips by volume shall be added and
thoroughly mixed dry again.
The pigment must be stable without any fading. It must be very
finely ground. The marble powder shall be from white marble
and shall be finer than IS Sieve No.30. The size of marble
chips may be between 1 mm to 20 mm.
Sufficient quantity to cover each visible area shall be prepared
in one lot to ensure uniform colour. Water to make it just
workable shall be added to a quantity that can be used up
immediately before it starts to set.
iii) Laying
The underbed shall be laid in panels. The panels shall not be more
than 5 m2 in area of which no side shall be more than 2.5 m long.
For exposed locations the maximum area of panel shall be 2.0 m2.
The panels shall be laid in alternate bays or chequered board
pattern. No panel shall be cast in contact with another already laid
until the latter has contracted to the full extent.
Dividing strips made of aluminium or glass shall be used for forming
the panels. The strips shall exactly match the total depth of under
bed plus topping.
After laying, the underbed shall be levelled compacted and brought
to proper grade with a screed or float. The topping shall be laid
after about 24 hours while the underbed is still somewhat 'green'
but firm enough to receive the topping. Slurry of the mixture of
cement and pigment already made shall be spread evenly and
brushed in just before laying the topping. The topping shall be
rolled for horizontal areas and thrown and pressed for vertical
areas to extract all superfluous cement and water and to achieve a
compact dense mass fully bonded with the underbed. The surface
of the topping shall be trowelled over, pressed and brought to a
smooth dense surface showing a minimum 75% area covered by
marble chips in an even pattern of distribution.
iv) Curing
The surface shall be left for curing for about 12 to 18 hours and
then cured by allowing water to stand on the surface or by covering
with wet sack for four days.
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The mix for the topping shall consist of 1 part cement and 1
part fine sand by volume.
c) Laying
The patent stone finish, including the under bed shall be laid in
alternate bays or in chequered board pattern. No panel shall
be cast in contact with another already laid till the contraction of
the latter has already taken place.
The maximum area of each panel shall be 3.5 m2 of which no
side shall be more than 2 m long.
A cement grout shall be applied and worked into the surface to
receive the finish, the underbed then laid, compacted and
levelled to proper grade with a screed or float. The topping
shall be applied evenly on the underbed while it is not fully set
but firm enough and rolled and pressed to get full bond. The
topping shall be trowelled to a dense finish to the satisfaction of
the Engineer-in-charge. All trowel marks shall be mopped out
with a soft cloth to give a clean smooth surface.
After the surface is sufficiently set, the finished floor shall be
kept moist for 7 days for curing. If desired the finish shall be
polished as directed by the Engineer-in-charge.
2.5.13.3.6 Metallic Hardener like Ironite finish
iii) Mix
Proportion of the metallic hardener shall be specified or as
indicated by the manufacturer. However, in absence of any such
direction 1 part metallic hardener shall be mixed dry with 4 parts
cement, by weight. To this mixture 6mm nominal size stone chips
shall be added in proportion of 1 part cement (mixed with hardener)
to 2 parts of stone chips by volume and uniformly mixed. Minimum
quantity of water shall be added to make it workable.
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iv) Laying
The concrete floor shall be laid as per specification 'Cement
concrete' and levelled up to the required grade. The forms, if any,
shall remain sufficiently projecting to take the finish. The surface
shall be roughened by wire brush as soon as possible. The finish
shall be laid while the concrete underbed is still very 'green' within
about 4 hours of laying of the latter. The finish shall be of uniform
thickness and even dense surface without trowel marks, pin holes,
etc. This topping layer shall be pressed firmly and worked
vigorously and quickly to secure full bond with the concrete base.
Just when the initial set starts the surfaces shall be finished smooth
with steel trowel.
The finished floor shall be cured for 7 days by keeping it wet.
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be completely free from glaze and the underside shall have ribs or
indentations for better anchorage with the fixing mortar.
The coloured tiles, when supplied, shall preferably come from one
batch to avoid difference in colour.
iii) Mix: Underbed
The mix for the underbed shall consist of 1 part cement and 3 parts
coarse sand by weight mixed with sufficient water or admix if
specified.
iv) Laying
Same as per clause 2.5.13.4.1(item iv)
v) Finishing
The joints shall be cleaned and flush pointed with white cement and
cured for 7 days by keeping it wet. The surface shall be cleaned
with soap or suitable detergent, washed fully and wipe with soft
cloth to prevent scratching before handing over.
2.5.13.4.4 Terrazzo Finish (Mosaic, etc.)
This finish consists of manufactured vitreous, glass, ceramic or
similar hard small pieces set in an underbed over a concrete or
masonry surface, already laid.
i) Thickness
The total thickness including the underbed shall be between 16 mm
and 25 mm.
ii) Terrazzo Finish
These shall usually be 6mm thick pieces of ceramic vitreous china,
tinted glass or similar hard wearing, strong and durable material in
desired shapes and sizes and patterns.
The supply shall come in the desired pattern in full or in sections
convenient for handling, stuck to pieces of strong thick paper on the
surface to be exposed. The gum used for this purpose must be
water soluble and non-staining. The sections shall be properly
marked to avoid mistakes and master drawing shall be available at
the site for guidance.
iii) Mix: Underbed
Same as clause 2.5.13.4.1(item iii) 3
iv) Laying
The specifications for laying if given by the manufacturer of the item
shall be followed provided it is approved by the Engineer-in-charge.
Otherwise clause 2.5.13.4.1(item iv) shall generally be followed.
However, instead of grey cement the slurry shall be made with
white cement to fix the panels.
The paper mounted patterns in sections shall be carefully placed
and pressed in position true to lines and levels. Earliest possible,
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the paper shall be peeled off and surface examined and cleaned,
joints flush pointed with white cement and cured for 7 days keeping
it wet.
2.5.13.4.5 Chemical Resistant Tiles Finish
This shall include all varieties of special tiles used for specific
chemical resistance function and an underbed over already laid
concrete or masonry.
i) The chemical resistant tiles, as per drawings shall be of the best
indigenous manufacture unless otherwise specified and shall be
resistant to the chemicals described in the drawings. The tiles shall
have straight edges, uniform thickness plain surface, uniform non-
fading colour and texture.
Glazed tiles if permitted to act as chemical resistant finish shall be
considered under clause.
Usually the chemical resistant tiles shall not absorb water more
than 2% by weight. The tiles shall have at least compression
strength of 700 kg/m2. The surface shall be abrasion resistant and
durable.
ii) Laying
The mortar used for getting or for underbed shall be durable and
strong. The grout which shall be to the full depth of tile, shall have
equal chemical resistant properties. Joints shall be pointed if so
desired. The setting and fixing shall be according to the
manufacturer's specification approved by the Engineer-in-charge.
2.5.13.4.6 Rubber, Vinyl or Asbestos Tile Finish
This shall include various types of tiles manufactured from rubber,
vinyl, etc. set with a sticker on concrete or masonry base. An
underbed may be required to secure desirable surface and grade.
i) Thickness
The thickness of the tiles shall be mentioned in drawings.
ii) Tiles
Unless otherwise desired the tiles shall be square of approved
dimensions. The tolerance in dimensions shall be 1.5 mm.
The face of the tiles shall be free from porosity blisters, cracks,
embedded foreign matters or other physical defects which effect
appearance or serviceability. All edges shall be cut true and
square. The colour shall be non-fading and uniform in appearance,
insoluble in water and resistant to each tile shall be marked on the
back legibly and indelibly with manufacturer's trade mark, the
thickness, sizes, batch number and date of manufacture.
Tiles shall be delivered securely packed and stored in clean, dry,
well ventilated place at a temperature near about to that the tiles
shall be called upon to stand ultimately.
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2.5.13.4.8 Stone Slab Finish: Sand Stone and Coarse Grained Stone Finish
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2.5.14.1 Scope:
The work in general shall consist of supplying and erecting and
installation of all metal doors, windows, ventilators, louvers, glazes
partitions, etc. as shown on drawings with all materials complete
excluding supply of glass and glazing.
2.5.14.2 Materials:
Steel sections used for fabrication of doors, windows, etc. shall be
standard steel sections as specified in I .S 1038 (latest edition) and
I.S 1361(latest edition) as specified in drawing.
Steel sheets for frames, shutters, louver blades, etc. shall be of
gauge mentioned in this specification.
Hardware and fixtures of the best quality from approved
manufacturers shall only be used. The Bidder shall specifically
state the particular manufacturer's materials be proposes to use. All
hardware and fixtures shall be able to withstand repeated use.
Door closers shall conform to I.S 3564 (latest edition) and shall be
suitable for doors weighing 61-80 kg unless otherwise stated. Each
closer shall be guaranteed against manufacturing defect for one
year and any defect found within this period shall be rectified or the
closer replaced free of charge. Concealed door closers shall be
either floor mounted or transom mounted, suitable for installation
with metal doors. It shall conform to the performance requirements
and endurance test stated in I.S 3564(latest edition).
The Contractor shall submit samples of each type of hardware to
the Engineer-in-charge. The approved samples shall be retained by
the Engineer-in-charge for comparison with bulk supply. The mastic
for caulking shall be of best quality from a manufacturer approved
by the Engineer-in-charge. In general, fixing of mastic on metal
frames shall be as per I.S 1081(latest edition) and/or as approved
by the Engineer-in-charge.
2.5.14.3 Fabrication:
2.5.14.3.1 Steel Doors, Windows, Ventilators, Louvers, etc.
i) Door Frames
Frames shall be fabricated from 0.8mm. Sheet. They shall be
mortised, reinforced, drilled and tapped for hinges and lock and bolt
striker. Wherever necessary, frames shall be reinforced for door-
closer. Welded construction with mitred corners shall be used.
Rubber door silencers shall be furnished for the striking jamb.
Loose 'T' masonry anchors shall be provided. Frames shall finish
flush with floor and adjustable floor anchors shall be supplied.
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the Contractor shall make provisions for openings in the door for
monorail beams. Doors shall close positively to exclude rainwater
from seeping in. Sliding doors shall withstand specified wind loads
without buckling or jamming. The door shall slide freely under all
ambient conditions.
v) Steel Windows, Sashes, Ventilators, etc.
These shall conform in all respects to I.S 1038 (latest edition) and
I.S 1361 (latest editions) and as shown on drawings. The details
as called for in the above codes shall be applicable for coupling
mullions.
All welds shall be dressed flush on all exposed and contact
surfaces.
Where composite unit openings are shown on drawings, the
individual window units shall be joined together with requisite
transoms and mullions. All windows shall be outside glazed, fixed
with putty or metal glazing beads.
2.5.14.3.2 Shop Coat of Paint
The shop paint for steel doors, windows etc. shall be best lead or
zinc chromate primer paint from approved manufacturers. All
surfaces shall be thoroughly cleaned of rust, grease, loose mill
scales, etc. and given one coat of shop paint. Portions like
mullions, transoms, etc. which will be inaccessible after assembly
of units shall be given an extra coat of paint before assembly.
Where called for in the drawings, all steel doors, windows etc. shall
be not dip galvanised to give a coating weight of 1 - 2 oz. per
sq.ft. One coat zinc chromate primer coat shall then be applied as
shop paint.
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2.5.15.1 Scope:
The work in general shall consist of supplying and fixing all glass
and glazing including all clips putty, mastic cement etc. wherever
required as shown on drawings and specification.
2.5.15.2 General:
The Contractor shall supply and install all glass and glazing as
required for various doors, windows, sashes, ventilators and fixed
louvers, miscellaneous glazing and partitions, unless otherwise
stated in the drawings or schedule. All glass shall be of superior
quality from approved manufacturer, having uniform refractive
index and free from flaws, specks and bubbles. The glass shall be
brought to site in the original packing from the manufacturer and
cut to size at site. The cut edges shall be straight and free from
chips, spalls or any other damages.
2.5.15.3 Materials:
a) Glare reducing or heat absorbing glass shall be approved
quality and special care shall be taken to grind smooth and
round off the edges before fixing.
b) Clear glass shall be flat drawn sheet glass and shall be at
least 4 mm thick. Sheet glass for doors shall be minimum
5.5 mm thick.
c) Wired glass shall be thick rolled glass with centrally
embedded 24G wire mesh or Georgian type. This may be or
clear or coloured glass, as shown in drawings or schedules.
d) Obscure glass shall have a cast surface on one side.
e) Coloured and figured glass shall be as per approved
sample.
f) The general, the putty shall conform to I.S 419 and be of
best quality from approved manufacturer. It shall be brought
to site in the manufacturer's original packing. Quick setting
putty shall be used for windows and sashes except when
glare-reducing glass is used where it shall be of non-setting
type.
g) Neoprene gaskets with snap fit glazing beds shall be fixed
as per manufacturer's instructions and shall sit snugly
against glass to give a leak proof installation.
2.5.15.4 Glazing, Setting and Finish:
All glazing clips, bolts, nuts, putty, mastic cement, etc. as required
shall be supplied by the Contractor.
All glass shall be thoroughly cleaned before putting in position.
Each glass panel shall be held in place by special glazing clips of
approved type. As specified in relevant IS Codes, four glazing clips
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shall be provided per glass panel, except for large panels where six
or more clips shall be used as per Engineer-in-charges instructions.
All holes that may be necessary for holding the clips, glazing beads
and all other attachments shall be drilled by the Contractor.
Glass panes shall be set without springing, and shall be bedded in
putty and back puttied, except where mouldings or gaskets are
specified. Putty, mastic cement etc. shall be smoothly finished to a
true even line. Obscure and figured glass shall be set with smooth
side out.
After completion of glazing work, the Contractor shall remove all dirt
stains, excess putty etc, clean the glass panes and leave the work
in perfectly acceptable condition. All broken cracked or damaged
glass shall be replaced by new ones at the Contractor's own cost.
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2.5.16.1 Scope:
This specification covers the design, supply of materials,
fabrications, delivery and erection of rolling shutter/grills with mortar
drives and/or manual operation including all accessories as herein.
All electrical works will be as per Indian Electricity Rules.
2.5.16.2 Components:
a) Slats for rolling shutters shall be made from tested bright cold
rolled, annealed MS strips, not less than 0.9 mm thick for
shutters up to 3.5 m wide and not less than 1.25 mm thick for
shutters 3.5 m wide and above, machine rolled at 755 mm
rolling centres, interlocking with each other. The profile will be
such as to prevent excessive deflection under specified wind
load.
b) Rolling grills shall be constructed out of 6 mm diameter rods at
35 mm on centres running horizontally flexibly connected with
vertical links spaced not more than 200 mm centres.
Alternatively, rolling grills shall be made from perforated slats of
approved design reinforced with 6mm diameter rods.
c) End looks shall be heavy type MCI/CI and shall be provided at
each end of alternate slate unless specified otherwise in the
schedule.
d) Bottom bars shall be finished with two angles not less than 6
mm thick for external shutters. A flexible contact leather strip
shall be applied to make tight contact with the floor.
e) Guides shall be of such depth as to retain the shutter under a
wind pressure of 150/sq.m or as specified in schedules.
f) Shaft shall be of steel pipe of sufficient size to carry the torsion
load with a maximum deflection of 1/360th of span. Grease
packed ball bearings or bushings shall be provided for smooth
trouble free operation.
g) Hoods shall be formed of not less than 20 gauge steel, suitably
reinforced to prevent sag.
h) Locks shall be slide bolt and hasp, or cylinder lock operable
from one or both sides. Provision to securing hand chain with
pad lock. Provision for removable handle for hand cranks, etc.
shall be made as described in schedule or as desired by the
Engineer-in-charge.
i) Power unit shall be suitable for 3 phases, 50 Hz, 415 volt AC
power supply and shall be either floor or wall mounted unit. The
motor shall be of sufficient capacity to move the shutters in
either direction at a speed of 0.3 m/s. In addition to the drive
unit (motor, Gear box, coupling) each standard power unit shall
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conditions. All control and locking devices shall give fault free
performance.
2.5.16.6.3 Guarantee
The Contractor shall give one year's guarantee for the successful
operation of the shutters. This shall be supported by a separate
and unilateral guarantee from the manufacturer of the shutters.
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2.5.17.1 Scope:
The work under this section shall include the supply and installation
of suspended ceiling using insulation/acoustic boards, plaster of
Paris boards, 'Perspex' etc. together with the suspension system as
shown on drawing or specified in Schedule with all materials labour
and equipment. The work shall also include providing of openings
in the ceiling for lighting, air conditioning diffusers etc, as shown on
drawings or instructed by the Engineer-in-charge.
Proprietary systems shall be installed in accordance with the
manufacturers instructions
2.5.17.2 Suspension System:
2.5.17.2.1 General
Suspension system shall consist of the grid supporting the ceiling
panels, intermediate runner supports for the grid if any and
hangers, wall angles etc. required to suspend the grid or the
runners from structural walls, slabs and beams or trusses.
All members of the suspension system shall be of sufficient
strength and rigidly to carry the ceiling boards or sheet in a true and
level plane without exceeding a deflection of 1/360th of their span.
All joints in ceiling panels shall run straight and cross joint shall be
at perfect right angles. Angle moulds where shown on drawings
shall be securely fixed to walls. All drillings of structural concrete or
welding to steel for installation of the suspension system shall be
included in the scope. All M.S sections used for supports, etc. shall
be given one coat of synthetic enamel paint over a coat of red lead
primer. All wood supports shall be painted with two coats of
'Solignum' or other approved wood preservatives before erection.
2.5.17.2.2 Metal Grid Suspension System
Aluminium grid ceiling system shall be of approved manufacturer.
Steel ceiling system shall also be jolly snap grid of approved
quality.
Angle cleats or other suitable fixing device shall be fixed to the
structural beam or slab above for fixing of hangers. Main runners
shall be hung by MS flats, angles or 12G or heavier galvanised tie
wire hangers at maximum 1.2 m centres. Extra hangers shall be
provided at light fixtures that are supported from the ceiling system.
The spacing of main and cross runners shall be shown on
drawings.
The cross tees shall intersect main runners in pattern shown on
drawing and positively locked together with intersection clips. All
perimeter areas shall have angle mouldings fixed to vertical wall
surfaces and end tees shall rest on the moulding, unless otherwise
shown on drawing.
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2.5.18.1 Scope:
This specification covers providing, laying, repairing, finishing,
curing, testing, protection, maintenance till handling over of roof
water proofing, insulation and allied works for buildings and at
locations covered under the scope of the Contractor.
2.5.18.2 Preparation:
2.5.18.2.1 Grading Underbed
The surface to receive the underbed shall be roughened and
thoroughly cleaned with wire brush and water. The joints in case of
pre-cast planks used for roofing shall be thoroughly filled in with 1:2
cement mortar using 'Impermo' or approved water proofing
compound. Oil patches if any shall be removed with detergent. The
surface shall be soaked with water and all excess water removed
just before laying of the underbed.
The underbed shall not be laid under direct hot sun and shall be
kept in shade immediately after laying so as to avoid quick loss
surface water. The underbed shall be cured under water for at least
7 days.
The underbed shall be laid to provide an ultimate run off gradient
not less than 1 in 120 and as directed by the Engineer-in-charge.
Up to an average thickness of 25 mm the underbed shall usually be
composed of cement and sand plaster. For higher thickness the
underbed shall be made with cement concrete.
The underbed shall be finished to receive the waterproofing
treatment direct or insulation as the case may be.
The grading plaster shall be average 25 mm thick maximum. It
shall consist of cement and coarse sand in the ratio 1:4 nominal by
volume. The sand and cement shall be thoroughly mixed dry and
then water added. Each batch of mix shall be consumed before the
initial set starts.
The plaster shall be fully compacted to the desired grade in
continuous operation. The surface shall be even and reasonably
smooth.
Concrete shall be used where the sub grade is more than average
25 mm thick. It shall consist of cement concrete 1:2:4 nominal mix
by volume with 12 mm down stone chips and coarse sand. The
aggregate shall be mixed dry and minimum quantity of water shall
be added to make the mix workable.
The mix shall be laid to proper grade, fully consolidated and
surface shall be smooth and even.
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2.5.18.2.2 Insulation
Where roof insulation is required, detailed proposals for its type,
supply and installation shall be submitted to the Engineer-in-charge
for approval.
2.5.18.2.3 Fillets
Fillets at junction of roofs and vertical walls shall be provided with
the same insulating material as provided for the main roof
insulation. The fillets shall be 150 mm x 150 mm in size unless
otherwise shown on drawings or instructed by the Engineer-in-
charge.
Where there is no insulation over roof slab, fillets shall be cast in
situ cement concrete (1:2:4) nominal mix by volume.
2.5.18.3 Installation:
2.5.18.3.1 Chemical Impregnation Water proofing External
i) Treatment
The treatment of water proofing basements and underground
structures comprises of forming a base around the structure by
creating an impermeable layer of chemical grout between the RCC
structure and adjoining strata resisting water infiltration.
The process comprises of laying an impermeable layer of chemical
grout horizontally between the base concrete bedding and the RCC
structure and is continued and carried along the outer surface of
the vertical walls up to a height of 300 mm above the adjoining
ground level. This water proofing shall be carried out in operations
as below.
1st course of cement mixed with chemical CH-9 shall be applied.
2nd course of 25 mm thick cement mortar 1:3 (1 cement: 3 coarse
sand) mixed with chemical CH-9.
3rd course of 25 mm to 35 mm thick red sandstone with joints
sealed with neat cement mixed with chemical CH-9.
4th and final course shall be of cement plaster 1:4 (1 cement: 4
coarse sand) on top of red sand stone mixed with chemical CH-9
with 12 cm gauge stone grit embedded in plaster. Similar process
shall be adopted for vertical faces.
ii) Measurement
Measurement shall be in square metre of the net actual surface
area grouted. The length and breadth shall be measured correct at
a cm.
iii) Guarantee
The Contractor through the specialised agency of sub-Contractor
shall give a guarantee against any leakage for a period of 10 years.
Any leakage or defect during this period shall be made good by the
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2.5.18.3.3 Damp Course Lining for Basements, Water Tanks and Foundations
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iii) NOTES:
a) Roofs
After specifications at 2.5.18.3.3 (item ii) has been laid, it will
be protected with tiles and every care is to be taken while
laying the brick or stone tiles so that the waterproofing is not
damaged or punctured by the sharp edged implements or
bricks, stone or walking over it with some shoes having nails
etc.
b) Basements
This waterproofing is laid on the floors and taken up on the
vertical walls 30 cm. above the ground level where a chase
50 mm wide and 50 mm deep is cut and the fabric tucked in.
After the water proofing is laid on the floors it will be
necessary to protect the same with RCC or cement concrete
thickness of which will depend on the hydrostatic pressure of
sub soil water and on the verticals by cladding wall with brick
or stone masonry. Prior to the laying of RCC or cement
concrete on floors a layer of bricks or stone is to be laid on
waterproofing (so that the fabric is not damaged by the sharp
edges of the ballast etc.) comprising:
- A layer of Bitumen felt fibre based self-finished felt type-2
grade of approved make.
- A layer of hot air blown asphalt @ 1.6 kg/m2.
c) General Conditions
The rates quoted shall include the cost of materials, labour
and all charges complete at the site of work, and for any
preparation civil work found necessary prior, during or after
the execution of the work which will have to be carried out,
and for making the surface reasonably smooth and dry by the
application of cement plaster before applying water proofing
felt as per specifications.
d) Guarantee
The Contractor through the specialised agency of sub-
Contractor shall give a guarantee against any leakage for 10
years. Any leakage or defects during this period shall be
made good by the Contractor through the sub-Contractor at
his own cost in a manner to be decided by the Engineer-in-
charge, to their entire satisfaction.
e) Measurement
As actually laid at site in m2.
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2.5.19.1 Scope:
This section includes supply of all materials, labour and incidentals
for water supply system.
2.5.19.2 Materials:
All materials, fittings, fixtures and appliances shall be of the best
quality conforming to relevant Indian standards and shall be
procured from approved manufacturers. Unless specifically allowed
by the Engineer-in-charge, the Contractor shall submit samples of
fittings and fixtures which will be retained by him for comparison
when bulk supplies are received at the site. Ultimate choice of type,
model and manufacture lies completely with the Engineer-in-
charge.
It shall be the responsibility of the Contractor to procure the
materials selected by the Engineer-in-charge. Hence orders are to
be placed with the manufacturers in time, so that the materials are
available at the site well ahead of their requirement.
The materials brought to the site shall be stored in a separate
secured enclosure away from the building materials. Pipe threaded
sockets, brass and other expensive items shall be kept under lock
and key. Fragile items shall be checked thoroughly when received
at the site and items found damaged shall not be retained at the
site.
2.5.19.2.1 Pipes and Pipe Fittings
Under scope of this specification, pipes and pipe fittings may be of
any or a combination of the following type:
a) Cast iron
b) Steel lined, coated with bituminous composition out
coated with cement concrete or mortar or galvanised.
c) Reinforced concrete
d) Pre-stressed concrete
e) Asbestos cement
f) Lead (Not to be used for potable water)
g) PVC
h) Copper
i) Brass
j) Wrought iron
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i) Cast Iron
a) Spigot and Socket Joints
Lead Joint: The joint is made by first caulking in clean spun
yarn up to half depth and filling the remainder by running in
molten lead taking care that no drops enters the joint and
then thoroughly caulking the lead. The lead need not extend
into the joint further than the back of the groove formed in the
socket. After completing the joint it shall not be allowed to
move. For rectification the joint shall be completely redone.
b) Flanged Joints
Flanged joints shall be made by jointing rings of good quality,
smooth and hard compressed fibre board of thickness not
less 1.5 mm and of such width as to fit inside the circle of
bolt. Diagonally opposite bolts shall be tightened in pairs and
in stages so that degree of all bolts in a joint is similar.
Damaged gaskets shall be replaced.
ii) Steel
Plain-ended steel pipes may be jointed by welding. Screwed and
socket joints shall be carefully tightened. Care shall be taken to
remove any burr from the ends of the pipes. Jointing compound, if
used, shall be lead free and approved by the Engineer-in-charge.
iii) GI Pipes
Threads shall be cut with sharp tools, and before jointing all scales
shall be removed from pipes by suitable means. The screw
threads of the pipe shall be cleaned out and the joint made by
screwing the fittings after treating the threads with approved pipe
jointing compound. Once a joint has been screwed up it shall not
be backed off unless the threads are re-cleaned and new
compound applied.
iv) Asbestos Cement Pipes
Socket and spigot ended pipes shall be jointed by caulking with
tarred gasket and grouted with 1:3 cement sand mortar.
v) Lead
Lead and lead alloy pipes shall be jointed with wiped solder joints.
vi) Concrete
Concrete pipes may be socket and spigot ended, collar or band
jointed. Jointing shall be effected by caulking with 1:3 cement sand
mortar.
vii) PVC
Manufacturer's instruction shall be followed. For beating approved
equipment with adequate control shall be used.
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Civil specifications NIT for 132kV Substation at Kusmunda OCP
i) Door 6 Nos.
ii) Window 4 Nos.
iii) Ventilator 2 Nos.
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and other defects, screw holes shall be counter sunk to suit the head
of the wood screws. All hinge pins shall be of steel with riveted heads.
- From fittings shall be bright finished or black enamelled or copper
oxidised.
- Brass fittings shall be bright finished brass, oxidised, or chromium
plated.
- Aluminium fittings shall be bright, finished anodised in choice shade or
as specified.
The screw used shall be of the same metal and finished as the fittings
and shall be of the required size. For aluminium fittings anodised steel
screws shall be used. The screw shall be driven with a screwdriver
and not hammered.
b) Butt Hinges:
Hinges shall be heavy quality of mild steel, brass, brass oxidised
aluminium or as specified. Butt hinges shall be cranked.
Brass and steel butt hinges shall conform to I.S 205(latest edition).
MS butt hinges shall be made from sheet; aluminium and brass
hinges shall be extruded type and made from extruded sections
c) Tower Bolts:
Shall be of mild steel, brass oxidised or aluminium as specified:
- Plate and straps shall be riveted the barrel bolt shall be cast including
the knob.
- Brass Tower Bolts: The bolt with knob shall be cast and rolled and
shall be made in one piece.
- Aluminium Tower Bolts: Shall be made out of extruded sections. Knob
shall be screwed to the bolt and riveted at the back.
d) Sliding Door Bolts (Aldrop):
These shall be of metal as specified, and shall have smooth sliding
action. MS and brass sliding bolts shall conform to I.S 281(latest
edition).
Brass sliding bolts shall be made from rolled brass. The hasp and
the bolt shall be in one piece. The fixing and staple bolts shall be
cast 6mm studs and shall be threaded, provided with round
washers and nuts of square of hexagonal shape
e) Handles:
- Iron handles - Shall be of the size specified and shall be made out of
sheet steel pressed into oval section. They shall conform to I.S 208(latest
edition) and shall be fixed with 2.5 cm long screws.
- Brass Handles - Shall of the specified size, shape and pattern made out of
cast brass. They shall conform to I.S 208(latest edition) and shall be fixed
with 2.5 cm long screws.
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i) General
The work shall be done by skilled carpenters as per details shown
on drawing or instructed by the Engineer-in-charge.
Framing timber and other work shall be close fitting with proper
wood joinery, accurately set to required lines or levels and rigidly
secured in place. The surface of frame etc. which will come in
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i) General
These shall conform to drawings in all details. No nail marks, etc.
shall be permitted. Plywood grains shall be matched to give a
uniform and pleasing appearance.
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ii) Partitions
Partitions shall be checked for rigidly of fixing and plumb.
iii) Pelmets
Pelmets shall be checked for rigidly of fixing and adequate
clearance of fixtures.
iv) Cupboard Shutters
Shutters shall operate smoothly without jamming and locks and
bolts shall engage securely.
v) Drawers
Drawers shall operate smoothly and have back stops to prevent
them from being pushed too far. Locks engage securely.
v) Loose Furniture
Furniture when placed on a level surface tables tops etc. shall be
horizontal and the pieces stand stable on legs or supports.
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2.5.21.1 Scope:
This shall include supply, fabrication and erection of miscellaneous
metal items of light nature in gates, grills, balcony and stair
handrails, partitions, structural mullions and transoms, ladders,
hangers, monorails, MS inserts, masonry anchors, shelf angles,
anchor bolts, fasteners, etc. as shown on drawing or as instructed
by the Engineer-in-charge. The above items shall be of fabricated
or cast MS section/aluminium/brass, cast iron, MS and galvanised
MS sheets, aluminium sheet, expanded metal, wire mesh etc. as
shown on drawings.
2.5.21.2 Fabrication or Casting:
2.5.21.2.1 General
All work shall be done according to approved shop drawings. All
workmanship shall be equal to the best practice in modern
structural or foundry shop.
2.5.21.2.2 Shop Connections
i) All shop connections shall be riveted or welded except when noted
otherwise on drawings.
ii) Welding of steel shall be done in accordance with the I.S 816
(latest edition) - Use of metal arc welding for general construction in
Mild steel. Welding of aluminium shall be done in accordance with
IS 2812 (latest edition) - Arc welding of Aluminium and Alloys.
Special care shall be taken to grind smooth all welded surfaces that
shall remain exposed to view. Welds shall be electrically
continuous if so required by the Engineer-in-charge.
iii) Shop Coat
Before leaving the shop, all metal work shall be thoroughly cleaned
by effective means of all loose mill scale rust and foreign matter.
Except where encased in concrete, all steel work shall be given
one coat of approved metal protective paint, applied by brush
thoroughly and evenly, applied to dry surface. When specified on
Schedule, steelwork shall be galvanised and painted with a coat of
zinc chromate primer. Aluminium surfaces which shall come in
contact with masonry shall be given one coat of bituminous paint.
2.5.21.3 Erection:
2.5.21.3.1 Bracing
The Contractor shall provide all necessary temporary guys and
braces to ensure alignments and stability of the members and to
take care of all loads to which the structure may be subjected,
including erection equipment and operation of the same.
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List of Vendors NIT of 132/33kV Sub-station at Kusmunda OCP
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List of Vendors NIT of 132/33kV Sub-station at Kusmunda OCP
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List of Vendors NIT of 132/33kV Sub-station at Kusmunda OCP
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List of Vendors NIT of 132/33kV Sub-station at Kusmunda OCP
52 On line UPS System : Novateur Electrical and Digital System Pvt. Ltd
Note : In case the bidder intends to supply the P&M from vendors not listed in the
Approved Vendor List , written approval of the Employer shall be taken, who after evaluating
the eligibility and qualification of such Vendors, may choose to include them in Approved
Vendor List.
Bidder in his bid shall furnish information for evaluation and qualification of such
vendors. The criterion and format for evaluation of vendor is given below.
In addition, the approved vendors of other Coal India Subsidiaries will also be
considered.
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PART I GENERAL
1.0 Name of the company
2.0 Nature of the company Proprietary/ partnership/
Private/ Public Limited)
(Attach photocopy of articles of association/
Registration/Partnership/Deeds etc.)
3.0 Registered office
4.0 Works address
5.0 Name of chief executive
6.0 Name of the person to be contacted for this bid
(Furnish photocopy of attorney)
7.0 OFFICE :
Telephone no :
Fax No:
E-mail :
Web site, if any
8.0 WORKS :
Telephone no :
Fax No:
9.0 Total area of the factory
Covered
Uncovered
Factory layout
10.0 Total number of employees
Managerial
Technical
Administrative
Support services
11.0 Organisation chart
12.0 Range of products manufactured
(Enclosed all relevant technical catalogue and
literature)
13.0. Year of commencement of manufacturing
PART II TECHNICAL
1.0 Details of major products manufactured
Type
Size
Description
Annual production for preceding three years
2.0 Has your product been tested by any agency? If yes,
indicate details, copies of qualification approval,
test certificates), test reports etc.
3.0 Foreign Collaboration ( if any)
Products covered
Name and address of collaborator
Status of collaboration
Scope of involvement and responsibility with
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List of Vendors NIT of 132/33kV Sub-station at Kusmunda OCP
1. PART I GENERAL
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
The General Manager (CMC),
S E C L,
Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: List of Schedules furnished in the offer.
Yours faithfully,
Date:
(Signature)
(Printed Name)
Place: (Designation)
(Firms Seal)
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
The General Manager (CMC),
S E C L, Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: Qualification Information
Place:
(Signature)
Printed Name
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 329
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
The General Manager (CMC),
S E C L, Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: Work completion schedule
Place: (Signature)
Printed Name
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 330
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
Dear Sir,
We hereby confirm total and unconditional acceptance of the General Terms and
Conditions of Contract, Additional Terms and Conditions of Contract, General
Technical Conditions, Erection Conditions of Contract, Special Terms and Conditions
given in Volume-I of the Bid document.
Yours faithfully,
Date:
Place:
(Signature)
(Printed Name)
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 331
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
Dear Sir,
Sub: Performance Guarantee
We declare that the we warrant that the equipment will be new and in
accordance with the Owner document and free from defects in material
and workmanship for a period of twelve (12) calendar months
commencing immediately on the satisfactory completion of the trial
operations. Guarantee/Warrantee received from the manufacturer will
be also extended to the Employer. The liability will be limited to the
replacement of any defective parts in the equipment under normal use
and arising solely from faulty design, materials and /or workmanship
and such defective parts are replaced free of cost at site.
Yours faithfully,
Dated:
(Signature)
Place: (Printed Name)
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 332
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
Dear Sir,
Yours faithfully,
Dated:
Place: (Signature)
(Printed Name)
(Designation)
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 333
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
2.7.6.0 SCHEDULE VI: Technical deviations (to be submitted in Part II of the offer)
To,
Dear Sir,
Yours faithfully,
Dated:
(Signature)
Place: (Printed Name)
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 334
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
2.7.7.0 SCHEDULE VII : Additional provisions included in the offer over and above
the specifications given in the Tender document (to be submitted in Part II of
the offer)
To,
Dear Sir,
Sub: Additional provisions included in the offer over and above the
specifications given in the Tender document
Yours faithfully,
Dated:
Place:
(Signature)
Printed Name
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 335
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
Dear Sir,
The following are the instruments which will be leased out by us free of
charge to SECL for conducting performance and efficiency tests on
equipment supplied and installed. Apart from these instruments, any
other instruments that will be essential for the purpose will also be
supplied by us free of charge. All instruments will carry calibration
certificates.
Yours faithfully,
Dated:
Place:
(Signature)
Printed Name
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 336
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
Dear Sir,
The Contractor shall furnish the list of mandatory spares along with the
specifications, quantity and price. The Employer will scrutinise the list and
order will be placed separately.
Yours faithfully,
Dated:
Place: (Signature)
Printed Name
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 337
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
To,
Dear Sir,
Yours faithfully,
Dated:
(Signature)
Printed Name
Designation
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 338
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
132 kV 33kV
2) Type
4) No. of units:
a) Material
b) Type
c) Area
d) Pressure
9) Clearance:
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 339
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) No. of NO contacts
b) No. of NC contacts
21) Dimensions
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 340
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
132kV 33kV
1) Manufacturers name and place of manufacture
2) Type
3) Model
4) Number of units
a) 1500 Amps.
b) 2500Amps.
c) 5000 Amps.
d) 10000 Amps
e) 20000 Amps.
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 342
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
132 kV 33 kV
2) Type
3) Rated Voltage
8) Number of cores
9) Core details:
Rated Class of Accuracy limit
Output Accuracy Factor
Core I
Core II
Core III
Core IV
Core V
Core I
Core II
Core III
Core IV
Core V
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 344
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
132 kV 33 kV
2) Type
8) Accuracy class
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 346
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
132 kV
1) Manufacturers name and place of manufacture
2) Type
3) Rated voltage:
4) Number of units
8) Type of mounting:
9) Type of operation
a) symmetrical (kA)
c) asymmetrical (kA)
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
b) Phase Factor
c) Natural frequency
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) Opening
b) Closing
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
- at tripping
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
2) Type
3) Rated voltage:
4) Number of units
8) Type of mounting:
9) Type of operation
a) symmetrical (kA)
c) asymmetrical (kA)
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
b) Phase Factor
c) Natural frequency
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) Opening
b) Closing
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
-at tripping
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
3) Number of phases
4) Number of units
5) Frequency
9) Type of cooling
a) HV Winding
b) LV winding
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 355
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) HV winding
b) LV winding
a) HV terminals
i) In oil
- Between phases
- Phase to earth
ii) In air
- Between phases
- Phase to earth
b) LV terminals
i) In oil
- Between phases
- Phase to earth
ii) In air
- Between phases
- Phase to earth
a) HV Winding
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
b) LV Winding
a) Sides
b) Bottom
c) Radiators
d) Cover
a) HV winding
b) LV winding
30) Minimum clear height for lifting the core and the
windings from the tank (m)
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) HV
b) LV
a) Radiator
b) Fans
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 358
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) HV winding (Ohms)
b) LV winding (Ohms)
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
i) Type
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) Name(s) of manufacturer
a) Name(s) of manufacturer
b) Model nos. and quantity
c) Type of protections provided
10) Details of various indicative devices provided for 132 kV
and 33 kV control panels and OLTC control panels
11) Sizes and types of wires used for internal wiring of various
control panels
12) Sets of various control switches and push buttons with related
functions provided
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 362
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
2) kVA Rating
3) Rated voltage
HV nominal : kV
HV highest system : kV
LV nominal : V V
LV highest system : V V
4) Rated Frequency
5) No. of phases
7) Vector group
8) Tapings
a) Range
b) No. of steps
c) Type of tapping
a) On oil : deg. C
b Windings : deg. C
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) HV side
b) LV side
c) Neutral
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 364
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
c) Oil : kg
d) Total mass : kg
a) Length : mm
b) Breadth : mm
c) Height : mm
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 365
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) Manufacturers name
c) Applicable standards
i) Breaker cubicles
ii) Busbar chamber
i) Clearance in air
i) Between phases
ii) Between phase and earth
i) MCCB panel
ii) MCB panel
k) MCCB
i) Makers name
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
x) Setting range
xii) No of phases
l) MCB
i) Make
v) No. of poles
n) Fuses
i) Make
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
ii) Type
o) Voltmeter
i) Make
ii) Type
p) Ammeter
i) Make
ii) Type
q) Indicating Lamps
i) Make
ii) Type
iii) Voltage
r) Push Buttons
i) Make
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
i) Maker's name
ii)Type
iv)Details of enclosure
ix)Electrical single line diagram with all components along with relevant details
x)Details of construction.
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
x) Drawings to be furnished:
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
b) Operating voltage
vi) Wiring Cable
a) Maker's name
b) Standard to which the cable conforms
c) Voltage grade, volts
d) Size of conductor, sq. mm
e) Conductor material
f) Insulation
vii) Junction Box
a) Maker's name
b) Make
c) Material and thickness
viii) Switch
a) Maker's name
b) Type
c) Rated voltage, volts
d) Current rating Amps.
ix) Constructional Details of lighting towers
x) Details of emergency lighting and safety lighting
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
a) Maker's name
b) Standard to which the cable conforms
c) Voltage grade, volts
d) Suitable for restricted earthed system (power cable)
e) Permissible voltage and frequency variation for satisfactory
operation.
f) Continuous current rating with single cable laid in air in an
ambient temperature for a maximum conductor temperature of
70 deg C, Amps.
g) De-rating factors for the following shall be indicated:
i) Variation in ambient air temperature (for cable laid in air)
from 30C to 50C in step of 5C.
ii) Variation in ambient ground temp. (for cables laid direct in
ground) from 15C to 40C in steps of 5C
iii) Grouping
h) De-rating factors for different spacing of cables considering
multi-core cables installed in horizontal formation in single row
as well as in different tiers-
i) Cables laid in concrete cable trenches with removable
covers.
ii) Cables laid in cable trays
iii) Cables laid in ground
iv) Depths of laying for cables laid to be directly in ground.
i) Short circuit current
i) Short circuit current, kA
ii) Duration of short circuit
iii) Conductor temperature allowed for the short circuit duty.
j) Conductor
i) Material
ii) Nominal cross sectional area, sq. mm
iii) Number and diameter of wires.
k) Insulation
i) Material
ii) Thickness
iii) Composition
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
33 kV 132kV 33 kV 132 kV
2) Place of manufacture
9) Electromechanical strength of
a) each unit
b) complete stack/string
a) one unit
b) complete stack/string
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
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Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
2.7.11 SCHEDULE XI: Price Bid (to be submitted in Part III of the offer) Vol-III of
the NIT
To,
Dear Sir,
Yours faithfully,
Dated:
Place:
(Signature)
(Printed Name)
Designation
Firm's Seal
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 379
SUB STATION BUILDING
BARBEDWIRE FENCING