TS-FIRE, PKG (1) - No. 087 - 03.11.09

NEELACHAL ISPAT NIGAM LIMITED DUBURI, ORISSA TECHNICAL SPECIFICATION OF FIRE FIGHTING FACILITIES FOR NINL PHASE -II
CONTENTS Chapter No. 1. 2. 3. 4. 5. ". 7. 8 9 1! 11 12 13 14 15 1" 17 18 19 Construction water Construction power Site meteorological data Tec nological #esign criteria $aterial andling %acilities Ci&il wor's Steel structure wor's (lectrical )nstrumentation S op Testing * +ainting +ac'ing * #ispatc (rection, site testing * Commissioning +ro-ect implementation sc edule * +rogress $onitoring +er%ormance Guarantee .ist o% drawings * documents to /e %urnis ed along wit t e o%%er .ist o% drawings and documents to /e %urnis ed a%ter placement o% order .ist o% tender drawings enclosed Descr pt o! General instruction to tenderer Pa"e Nos. Fro# To 1 8 8 9 1! 14 4" "4 72 74 83 99 1!4 1!5 123 125 125 12" 129 7 13 45 "4 72 74 83 99 1!4 1!5 122 124 12" 129 -
PREPARED B$ Cha!'resh G(pta ADE

2009.MECON Limited. All rights reserved
CHEC%ED B$ L. Mahto Sr. Ma!a"er
APPRO&ED B$ P.S. Rao DGM
TS for Fire Fighting Facilities !ac"age No. 0#$%
01.0 !1.1 !1.2
GENERAL INSTRUCTION TO THE TENDERER 0)0. now intends to install steel ma'ing units in t e proposed p ase )) e1pansion wit t e state o% art tec nolog2. )t is proposed to install t e %ollowing as part o% t is pac'age in p ase )) e1pansion at #u/uri in 3rissa State 4ater /ased %ire %ig ting s2stem consisting o% pump ouse along wit static water tan', pumping s2stem, interplant pipe networ', 5ire 2drants, .anding &al&es, 5ire %ig ting oses and 0o66les etc.
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)n p ase 7), alread2 %ire water networ' is erected and commissioned. )n p ase 7)), new %ire water networ' is to /e installed. 8lso at certain places new networ' is to /e interconnected wit t e e1isting p ase 7) networ'. 8 tentati&e routing plan is indicated in t e enclosed drawings. T e Tenderer s all &isit t e site %or assessing pre&ailing site conditions and satis%2 imsel% %ull2 wit t e scope and e1tent o% t e wor' in&ol&ed prior to su/mission o% is o%%er. T is pac'age s all /e e1ecuted on a lump-sum Turn'e2 /asis. 9owe&er, t e +urc aser reser&es t e rig t to accept :re-ect t e o%%ers in totalit2 or split t e scope o% wor' or alter t e speci%ied ;uantit2 o% suppl2: ser&ices or delete an2 item:ser&ice %rom t e scope o% wor' wit out assigning an2 reason. T e purc aser also reser&es t e rig t to procure directl2 some items:e;uipment:s2stem as per t e design, speci%ications. )n suc case complete manu%acturing drawings are to /e gi&en /2 t e success%ul tenderer. T e Success%ul Tenderer s all suppl2 <asic #esign, #etailed (ngineering and $anu%acturing drawings, Speci%ication o% all t e items:e;uipment /ased on t e descriptions gi&en in c apter 5.!. T e tenderer, owe&er, as t e option to su/mit is proposal /ased on is own designs w ic e considers suita/le and capa/le o% meeting t e re;uired operation * dut2 conditions. #e&iations %rom t e speci%ication and standards, i% an2, s all /e /roug t out clearl2 wit proper -usti%ications. T e scope o% wor' o% tenderer s all co&er all suc supplies and : or ser&ices w ic are re;uired to ensure completeness o% t e suppl2 and success%ul integrated sa%e operation o% all t e new %acilities along wit e1isting %acilities. 8n2t ing not co&ered in t is speci%ication /ut essential %or proper installation, operation and maintenance s all /e included /2 t e Tenderer in is o%%er and t e reasons %or suc inclusions s all /e clearl2 stated.
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T e Tenderer s all stud2 t e speci%ication and satis%2 imsel% t oroug l2 regarding t e wor'a/ilit2 o% t e s2stem as a w ole and s all ta'e t e responsi/ilit2 o% per%ormance guarantee. )% t e Tenderer %eels t at an2 tec nical data o% t e plant and %acilities indicated in t is speci%ication in is opinion is unsuita/le, e s all indicate t e same and su/mit an alternati&e proposal on t e /asis o% is tec nical consideration. Standard <id #ocument /eing issued separatel2, includes t e pre%erred ma'e %or &arious items. Tenderer s all ad ere to t e same and indicate t e names o% supplier in t e o%%er. 5ire %ig ting s2stem s all compl2 wit t e latest regulations and stipulations o% t e T8C, )nspector o% 5actories and ot er applica/le statutor2 /odies o% Go&t. o% )ndia and Go&t. o% 3rissa w ere&er applica/le %or designing, installation and commissioning. )t is t e responsi/ilit2 o% Success%ul Tenderer to satis%2 t e rele&ant aut orities and o/tain clearances %rom statutor2 aut orities and ot er concerned agencies. 8ll costs on t ese counts s all /e /orne /2 Success%ul Tenderer. Statutor2 /odies s all include /ut not limited to t e %ollowing= >i? >ii? >iii? >i&? >&? >&i? >&ii? )ndian Standards pu/lis ed /2 t e <ureau o% )ndian Standards. )ndian (1plosi&e 8ct. )ndian 5actor2 8ct and 5actor2 @ules o% t e State. )ndian (lectricit2 @ules. $odel Codes o% Sa%et2 regulations %or industrial (sta/lis ments issued /2 )nternational .a/our 3rganisation >).3?. Tari%% 8d&isor2 Committee >T8C?. 8n2 ot er rele&ant:standards.
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T e Tenderer s all stud2 t e General Speci%ication and con%irm t e acceptance o% t e same in t e o%%er. )n case o% an2 de&iation is considered /2 t e Tenderer, t e same s all /e clearl2 indicated in t e o%%er. Standardisation in design and construction o% e;uipment and s2stem intended %or identical duties s all /e pre%erred. 8ll li'e parts o% similar e;uipment are to /e interc angea/le. 4or'mans ip and material s all /e o% good ;ualit2 suita/le %or purpose intended and in accordance wit ig est standards and practices %or e;uipment o% class co&ered /2 t e speci%ication. Tenderer s all note t at incomplete o%%er will /e lia/le %or re-ection.
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8ll e;uipment s all /e suita/l2 eart ed. .i%ting lugs s all /e pro&ided in t e e;uipment w ere&er necessar2 %or maintenance:erection. Tools * Tac'les Tenderer s all include in is tender special tools and tac'les, i% an2 re;uired %or normal operation and maintenance o% t e e;uipment. Consuma/les * .u/ricants T e o%%er s all include in%ormation on t e speci%ications, ma'e including e;ui&alent /rand names and ;uantities o% all consuma/les materials suc as lu/ricants: diesels, Catal2st, %lus ing oils re;uired during start-up, commissioning, initial %illing and 2earl2 re;uirements %or normal operation. )temi6ed unit prices s all /e indicated %or t ese items. T e Success%ul Tenderer s all suppl2 suc material re;uired %or start-up, commissioning, initial %illing and per%ormance guarantee test as well as %or one 2ear consumption a%ter commissioning. #rawings * #ocuments T ese s all /e as per re;uirement o% Tec nical Speci%ication and Special )nstructions to Tenderer. )nspection * Testing (;uipment s all /e inspected stage wise /2 +urc aser: (ngineer in accordance wit tests indicated /2 tenderer in $(C30 Standard A8+. Tenderer s all %urnis A8+ along wit o%%er. )nspection and appro&al at an2 stage o% manu%acture: %a/rication s all not a/sol&e t e manu%acturer: %a/ricator o% is responsi/ilit2 %or t e suppl2 o% %inis ed e;uipment to meet speci%ications. (;uipment or parts t ereo% materials and weld -oints %ound to a&e de%ects, improper %a/rication, e1cessi&e repairs or not meeting t e re;uirements o% t e speci%ication s all /e su/-ect to re-ection e&en i% suc conditions are disco&ered a%ter acceptance at manu%acturerBs s op. 8ll drawings :documents, designs, calculations etc. supplied /2 t e Tenderer under t e contract s all remain t e propert2 o% purc aser w o s all a&e t e rig t to use t em %or %uture pro-ects or procurement wit out an2 additional cost re%erence to Tenderer. Success%ul Tenderer s all 'eep t e site reasona/l2 clean during e1ecution o% -o/s %rom all unnecessar2 o/struction, store or remo&e an2 surplus material clear awa2 an2
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wrec'age, ru//is or temporar2 wor's %rom t e site and remo&e an2 contractorBs e;uipment no longer re;uired %or e1ecution o% t e contract. 8%ter completion o% t e wor' t e Success%ul Tenderer is to and o&er clear site de&oid o% all de/ris, unused material etc. to t e satis%action o% purc aser. !1.23 )n case purc aserBs an2 e;uipment >ot er t an t ose w ic are under TendererBs scope? are damaged during e1ecution o% wor', t e same s all /e restored to earlier condition /2 Success%ul Tenderer at no e1tra cost to purc aser. Success%ul Tenderer s all a&e ade;uate e;uipment and tools and tac'les li'e eart mo&ing e;uipment, cranes, winc derric', c ain pulle2 /loc's, welding sets, -ac's, gas cutting sets, gas regulators, grinding w eel etc %or smoot wor'ing at site. 8n2 s ort %all in a/o&e s all /e made good, i% pointed out /2 site engineer. +ainting 8ll t e e;uipment s all /e t oroug l2 cleaned and %reed %rom rust and scale. Sur%ace preparation and painting s all /e done in accordance wit speci%ication %or +ainting. S op painted e;uipment:items s all /e touc ed up as re;uired a%ter erection as per painting done /2 t e supplier o% t ese items. Tec nical speci%ication %or &arious items s all also /e re%erred %or special painting re;uirement. +(@T 7 C+$ #iagram T e Success%ul Tenderer s all su/mit detailed +(@T 7 C+$ diagram /ot in so%t cop2 and ard cop2 in $.S. +ro-ect:+rima&era li&e pro-ect data %or continuous monitoring to t e purc aser. T is +(@T 7 C+$ diagram s all co&er t e sc eduled status o% all %unctions o% t e pro-ect including, /ut not limited to t e %ollowing= a? /? c? d?
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+reparation o% <asic #esign +ac'age #etailed #esign * (ngineering +rocurement o% (;uipment (rection o% $ec anical (;uipment
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e? %? g? ? i? -? '? !1.2".3
(rection o% (lectrical )tem. (rection o% pipe line * .a2ing o% electric ca/les (rection o% )nstrumentation. (rection o% 5ire 2drants Testing, +re-Commissioning )nsulation * +ainting Start-up * Commissioning
4it in %i%teen >15? da2s o% t e award o% wor' or prior to t e 'ic'-o%% meeting, w ic e&er is earlier, t e Success%ul Tenderer s all pro&ide t e +urc aser wit t e detailed +(@T- C+$ diagram as mentioned a/o&e and a%ter wor' as started, issue updated statements on t e progress and: or completion o% t e listed acti&ities on a wee'l2 /asis. T e Success%ul Tenderer s all also deli&er on a mont l2 /asis to t e purc aser an updated +(@T 7 C+$ diagram s owing c anges in pro-ect status as o% t e end o% t e pre&ious mont . T is diagram s all /e deli&ered on or /e%ore t e 5t o% eac mont . T e Success%ul Tenderer s all pro&ide additional e%%ort w ere&er t e sc eduling s own on t e +(@T 7 C+$ diagram indicates a possi/le dela2 in t e completion date. Suc additional e%%ort ma2 re;uire an increased deplo2ment o% e;uipment and: or personnel wor'ing in 3 s i%ts. 8ll e1tra costs including cost towards proper lig ting %or wor'ing in 3 s i%ts incurred /2 t e Success%ul Tenderer in order to pre&ent a possi/le dela2 in t e completion date will /e to t e Success%ul TendererBs account. T e Success%ul Tenderer s all noti%2 t e +urc aser wit in twent2 %our >24? ours o% an2 occurrence, w ic ma2 ad&ersel2 a%%ect t e completion date o% t e pro-ect. T e Success%ul Tenderer s all also noti%2 t e +urc aser, at least once in e&er2 wee', t e status o% critical items, w ic could a%%ect t e completion date o% pro-ect. )n addition, t e Success%ul Tenderer s all include a statement o% proposed remedial action %or e1pediting t ese items. +rogress @eport T e Tenderer s all guarantee ad erence to t e time sc edule %ailing w ic t e purc aser s all a&e t e li/ert2 to cancel t e order at an2 stage. Success%ul Tenderer s all %urnis +(@T c art %or purc aserBs appro&al.
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8%ter placement o% order t e Success%ul Tenderer s all su/mit regular progress report on mont l2 /asis. T e %ormats and sc edules o% su/mission s all /e mutuall2 discussed and agreed. (mplo2ment o% Tec nical Sta%% /2 Success%ul Tenderer T e Success%ul Tenderer s all pro&ide all necessar2 superintendence during t e e1ecution o% t e wor's /2 appointing suita/le num/er o% ;uali%ied (ngineers and sta%% and %or so long t ere a%ter as is considered necessar2 %or t e proper %ul%illment o% t e contractorBs o/ligations under t e contract. T e Success%ul Tenderer s all depute competent and aut ori6ed engineer:sta%% or representati&e o% t e contractor appro&ed in writing /2 purc aser >w ic appro&al ma2 at an2 time /e wit drawn? is to /e constantl2 on t e wor's to ensure proper per%ormance o% ;ualit2 o% wor' and s all gi&e is w ole time to superintendence o% t e same. )% suc appro&al is wit drawn, t e contractor s all as soon as is practica/le > a&ing regard to t e re;uirement o% replacing im ereina%ter mentioned? a%ter recei&ing written notice o% suc wit drawal, remo&e t e representati&e:sta%% %rom t e site and s all not t ere a%ter emplo2 im in an2 capacit2 w atsoe&er and s all replace im /2 anot er sta%% : representati&e w o s all recei&e on /e al% o% contractor directions and instructions %rom purc aser : consultant. 4eig ts * +rices T e prices ;uoted s all remain unc anged t roug out t e pro-ect. T e tenderer s all ;uote %or item wise weig ts and prices %or suppl2 under t e %ollowing su/- eads. a? #esign * (ngineering. /? (;uipment. c? 92drants and %ire %ig ting %ittings. d? (lectrics. e? )nstrumentation and control. %? 3t er accessories, i% an2. g? (rection * complete erection super&ision >under di%% electrical, instrumentation separatel2?. ? Testing , Trial run and commissioning.
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eads- mec anical,
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T e tenderer s all include in is ;uotation all commissioning spares and special tools and tac'les re;uired %or erection, commissioning, operation and maintenance o% t e e;uipment to /e supplied.
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T e tenderer s all include in is ;uotation all spares re;uired %or operation and maintenance o% e;uipment %or 2 2ears normal operation. T e tenderer s all include in is ;uotation all insurance spares re;uired %or t is pac'age. T e tenderer s all note t at 0)0. will suppl2 pipe, &al&es, pipe %ittings >/idder to %urnis %ittings <3A?, encasing pipes, cement, rein%orcement steel and /asic structural steel sections as a %ree issue item. Tenderer to get t em issued %rom t e purc aserBs stores. 9andling %rom stores to erection site, cutting o% rein%orcement rods to t e re;uired si6e, and cutting * welding o% structural sections as per re;uirement is in t e scope o% wor' o% t e tenderer. T is speci%ication s all /e read in con-unction wit t e %ollowing documents irrespecti&e o% w et er attention to t e same as /een speci%icall2 drawn or not= 0otice )n&iting Tender and Commercial +art. General Tec nical Speci%ication. General instruction to t e tenderers GS-!1. General speci%ication %or ;ualit2 s2stem GS-!5. General Speci%ication %or +ainting GS-!2. General Speci%ication %or electrical GS-!3. +re%erred ma'es o% (;uipment $(C:A"93:11:37:#3C-!2, @-!. and suppl2-#ocument no.
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3t er documents as re%erred in t e &arious c apters o% t e speci%ication.
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T e intent o% t is speci%ication is to %urnis t e re;uired tec nical details to ena/le t e Tenderer to su/mit t eir /est o%%er on Cturn-'e2D /asis as per t e scope o% wor'. Auali%2ing criteria Tenderer s all a&e pre&ious e1perience in designing and commissioning o% similar capacit2 >(;ual or ig er capacit2? %ire %ig ting s2stem. T e tenderer s ould a&e e1ecuted at least one pro-ect o% t is magnitude or /igger in t e last %i&e 2ears. Tenderer s all su/mit wit is o%%er a statement o% a similar capacit2 %ire %ig ting s2stem designed and commissioned /2 im during t e last %i&e 2ears. T e tenderer s all also su/mit necessar2 documents in support o% t e same.
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)*.) !2.1
CONSTRUCTION +ATER T e Contractor will a&e to ma'e is own arrangements %or water re;uired %or and during construction, testing, %lus ing etc. 9owe&er, +urc aser ma2 suppl2 construction water at one point. 0o dela2 or e1tra c arges %or ma'ing arrangement %or construction water will /e admissi/le on account o% non suppl2 o% t e same /2 t e +urc aser. CONSTRUCTION PO+ER T e Contractor will a&e to ma'e is own arrangements %or construction power at t e %ire water pump ouse. 9owe&er, t e +urc aser ma2 pro&ide construction power at 415 E, 3 p ase 4 wire 8C suppl2 at one point >single %eeder?. T e contractor s all ma'e is own arrangements to la2 and maintain necessar2 ca/les, distri/ution lines and wiring at is own cost %rom t e +urc aserBs distri/ution /oard. T e contractor s all ensure t at t e electrical e;uipment emplo2ed are suc t at t e aggregate power %actor does not %all /elow !.8 at t e +urc aserBs terminal point. T e contractor s all suppl2 and install switc es, %use units o% suita/le rated capacit2 separatel2 %or power and lig ting on a %rame pre%era/le o% steel and pro&ide rain water protection co&er on t e switc es. T e installation s all /e made as per rele&ant rules. T e contractor s all suppl2 and install all distri/ution ca/les, wires etc. o% t e rated capacit2 %or t e wor' starting %rom t e source o% power at is own cost. 9e s all emplo2 electricians a&ing &alid electrical licence %or carr2ing out t e installations as well as %or t e maintenance wor's. T e contractor s all pro&ide proper %acilities to +urc aser or is aut ori6ed representati&es %or inspecting is temporar2 electrical installations as and w en re;uired. T e contractor s all immediatel2 attend to t e de%ects so pointed out during t is inspection including replacement o% %ault2 ca/le, switc es etc. T e contractor s all /e responsi/le %or all damages, losses etc. due to %ire or due to is negligence /2 improper installation, operation and:or maintenance o% is part o% installations. T e contractor s all ma'e is own arrangements %or alternati&e source o% power in case o% un-a&oida/le %ailure o% suppl2.
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S te #eteoro-o" ca- 'ata.A r Te#perat(re #r2 /ul/ #r2 /ul/ 4et /ul/ 4et /ul/ $a1imum $a1imum (1treme ma1imum (1treme minimum Re-at /e H(# ' t0 $a1imum $inimum Ra !1a-$a1imum rain%all in 24 rs + !' Pre'o# !a!t 2 !' ' rect o! a? /? c? Sout -4est to 0ort - (ast Sout to 0ort 4ind speed 7 18!-2!! H$: r >super c2clone prone area = 321.8mm = = 84G 57G = = = = = = = = 27.7!C >$ean? 31."!C >$a1? 23.2!C >$ean? 27.2!C >$a1? 41."!C >$a2? 1!.8!C >Fanuar2? 4".7!C >Fune, 1942? 8.3!C >Fanuar2, 1934 : #ecem/er, 1937?
A-t t('e A/era"e E-e/at o! a3o/e Mea! Sea Le/e- 4MSL5. 6)#. Appro7. co!ta# !a!ts ! a r C32 C292 C94 C294 C29" Cn9m
= = = = = =
35! 7 45! 1 5 1 1 !.5
++$ >$a1? ++$ ++$ ++$ ++$ ++$

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Tech!o-o" caScope o1 2or8 T e scope o% wor' o% t e tenderer co&ers design, engineering, procurement o% materials, %a/rication : 8ssem/l2, s op testing, s op painting, road : rail wort 2 pac'ing, loading, transportation to plant : site, unloading, storage at site, watc * ward, unpac'ing, transportation to erection site, andling at site, erection, site testing, site painting, commissioning, per%ormance guarantee tests o% complete water /ased %ire %ig ting s2stem along wit electrics, instrumentation and material andling %acilities etc. as descri/ed in su/se;uent clauses on turn'e2 /asis. T e scope also includes a. Su/mission o% drawings, tec nical design calculation etc. %or appro&al o% +urc aser:consultants and t e -o/ s all /e e1ecuted as per appro&ed drawings. Stores >co&ered, unco&ered and 8ir conditioned i% necessar2? wit well e;uipped o%%ice lig ting. $aterial andling de&ices including underslung crane, monorail, and all ot er connected wor's. Securit2 watc and ward sta%% and %ire %ig ting arrangement at site. 8n2 special instruments re;uired %or per%ormance testing at is own cost, and t e2 ma2 /e ta'en /ac' a%ter completion o% suc +.G. test. T e contractor s all indicate t e accepta/le accurac2 o% instruments e proposes to /ring %or +.G. test along wit Cali/ration Certi%icate. )nitial %ill o% diesel, oils and lu/ricants upto +.G. tests as applica/le. Suppl2 spares. . Suppl2 o% special tools, tac'les and ot er accessories re;uired %or erection, commissioning and operation o% t e plant. o% commissioning
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/. c. d. e.
%. g.
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i.
(rection o% t e all t e &al&es >&al&es * its %ittings are %ree issue item /2 0)0.? at site, carr2ing out site tests, commissioning including +.G. test. Sur%ace cleaning and painting o% all e;uipment and piping at manu%acturerBs wor's as well as %inal painting at site a%ter erection. Complete piping networ', along wit supports etc. > pipes, %ittings, encasing pipes, steel structures %or pipe supports are %ree issue item /2 0)0.. 5ittings ;uantit2 s all /e indicated /2 t e success%ul /idder to t e client %or necessar2 procurement?. Sur%ace cleaning, wrapping * coating o% underground pipelines, Sur%ace cleaning * painting o% o&er ground pipelines * structures. Suppl2 o% %oundation /olts, /ase plates and ot er accessories %or all e;uipment. 8ll anc or /olts, slee&es and ot er inserts in t e concrete re;uired %or t e e;uipment and accessories. @CC &al&e c am/ers >including design * construction?, t rust /loc's, area drainage >o% t e %ire %ig ting pump ouse area?, connecting t e same to plant storm water sewerage networ', etc. 8rrangement >wit all materials * e;uipment? %or drawing t e water %rom t e T.3.+. upto t e site >w ere&er re;uired? %or 2dro testing and %lus ing. Crosso&ers, structural wal'wa2, plat%orm, etc t ose are re;uired %or crossing t e pipes, %or operation o% &al&es. 8rrangement %or power suppl2 to e1 aust %ans >5nos.? a&ing eac motor capacit2 o% !.2 'w %or %ire water pump ouse. Site Grading o% t e area o% t eir scope o% wor'. Compre ensi&e )nsurance %rom #espatc till Commissioning. Suppl2 o% %ire %ig ting pumps >electrical * diesel engine dri&en?, -oc'e2 pumps, 2drants, ose ca/inet, ose, /ranc pipe, no66le and no66le spanner etc.
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l. m. n. o.
p.
;.
r.
s. t. u.
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8n2 ot er %acilities to complete t e pac'age as per s2stem re;uirements wit in t e de%ined /atter2 limits and as detailed out in respecti&e part o% t is speci%ication and ando&er to t e purc aser an 3perating +lant a%ter conducting all t e per%ormance guarantee tests to t e satis%action o% t e purc aser. 8n2 additional e;uipment or material t oug not speci%icall2 mentioned in t is tec nical speci%ication /ut is re;uired to ma'e t e s2stem complete or %or ensuring sa%e * proper operation and maintenance or to ac ie&e t e guaranteed per%ormance s all deemed to /e included in t e scope o% wor' o% t e contractor and s all /e pro&ided /2 im at is own cost. T e enclosed drawings are deemed to /e su%%icient %or t e tenderer to assess t e nature and ;uantit2 o% t e wor' in&ol&ed to ;uote is price %or t e a/o&e -o/. T e tenderer s all care%ull2 go t roug t e drawings. 0o price increase on account o% an2 de&iations %rom t e drawings will /e admissi/le. T e Contractor s all prepare t e detailed wor'ing drawings /ased on t e enclosed tentati&e la2out drawings. T e Contractor s all design t e complete s2stem %ollowing good engineering practices and standards. T e detailed scope o% design s all include = #e&elopment o% t e pumping sc eme. 5inalisation o% e;uipment la2out. #esign and routing o% pipes, pipe networ's along wit pipe supporting structures, ca/les, etc. #esign o% complete electrics, instrumentation and material andling %acilities.
!5.!1.4
!5.!1.5
!5.!1." !5.!1.7
!5.2 !5.!2.1
Descr pt o! o1 2or8. 4ater /ased %ire %ig ting s2stem s all consists o% i? ii? )ndependent 5ire water pump ouse >@CC construction?. Static water tan' wit two compartments a&ing total e%%ecti&e &olume o% a/out 11!! m3>i.e. 2 ours aggregate pumping capacit2?, wit suita/le isolation arrangements at outlets in suc a wa2 t at an2 o% t e compartment can /e ta'en out o% ser&ice wit out re;uiring s utdown o% o&erall s2stem. 5ire water pumps=
Page 13 of &29
iii?
$ain %ire water pumps, 2nos.>24I!S?, (lectrical dri&en eac o% capacit2 273m3: J88m4c. $ain %ire water pump, 1no.>Stand/2?, #iesel engine dri&en a&ing capacit2 o% 273m3: J88m4c. Foc'e2 pumps 2nos.>14I1S?, (lectrical dri&en eac o% capacit2 1!.8m3: J88m4c. i&? )ndependent pressurised %ire water piping networ' consisting o% a. +ipe networ' wit %ormation o% loops. /. Kard 2drants and internal 2drants at regular inter&als. c. +ipe %ittings * pipe supports. d. Eal&es %or isolation o% pipe loops >%or maintenance? inside t e @CC c am/ers. e. Eal&es prior to 2drants. %. @CC &al&e c am/ers. g. (ncasing pipes. 2nos. o% 15m long ose %or eac internal 2drant * 1no. 3!m long ose %or eac 2ard 2drant s all /e pro&ided along wit %ittings %or eac 2ard 2drant. 1no. o% ose /o1 %or eac landing &al&e to 'eep ose, /ranc pipe, no66le and spanner. Supporting structural %rame %or ose /o1es. Ta'ing tapping %rom t e ma'e up water networ' wit an isolation &al&e along wit @CC c am/er, la2ing pipeline %rom t e tapping point to t e static water tan' %or %illing t e same wit motori6ed &al&e at t e static water tan'. 8n isolation &al&e >gate &al&e? prior to as well as a%ter t e motor operated &al&e * a /2pass &al&e >gate &al&e? %or t e motor operated &al&e and %lowmeter s all /e pro&ided at t e upstream line.
&? &i? &ii?
!5.!2.2
Tech! ca- re9( re#e!ts 1or 1 re 1 "ht !" s0ste# i? T e 2drant networ' s all /e designed /ased on T8C re;uirement stipulated in clause no. 7.5.1! * 0.<.2 T e 2drant s2stem s all /e 2draulicall2 so designed t at w en al% o% t e aggregate pumping capacit2 is /eing disc arged at t e %art est : 2draulicall2 most remote point and t e ot er al% in t e most &ulnera/le area enroute, a minimum running pressure o% 3.5'g:cm2 is a&aila/le at t e %ormer point and rate o% %low o% water does not e1ceed 5m:sec an2w ere in s2stem. 0o. o% %ires to /e considered simultaneousl2= 2nos.
Page 14 of &29
ii?
iii? i&? &? &i? &ii?
0o. o% 2drant wor'ing in eac %ire= 4nos. 5low t roug eac 2drant= "!!lpm >minimum?.
Categor2 o% a6ard= 3rdinar2 a6ard. )nter&al /etween two consecuti&e 2ard >3utdoor? 2drants= 45m >appro1.?. )nter&al /etween two consecuti&e internal 2drants= 8ppro1imatel2 3!m in o%%ice /uilding, ot er process /uildings etc. DESIGN CRITERIA
)6.) )6.: !".!1.1
DESIGN CRITERIA FOR PUMP HOUSE T e la2out o% t e &arious e;uipment inside t e pump ouse s all /e designed /2 t e tenderer 'eeping in &iew t e sa%et2 o% t e personnel, accessi/ilit2 o% e;uipment and space %or maintenance. T e +ump ouse s all /e o% ci&il construction > a&ing @CC columns and @CC roo%?, closed on all sides and s all /e pro&ided wit minimum two entries. 3ne o% t e entries s all /e pro&ided wit rolling s utters a&ing space pro&ision o% truc' entr2. (;uipment la2out including design load data, e;uipment %oundation si6e, la2out o% pump ouse, details o% electrics, ca/le la2out etc s all /e %urnis ed /2 t e Tenderer. T e ma'eup water s all /e drawn into t e static water tan' t roug a %loat and motori6ed &al&e. 8n isolation &al&e, %lowmeter and necessar2 control &al&e s all /e pro&ided at t e upstream o% t e %loat &al&e. T e static water tan':suction c am/er s all /e designed as per t e standard o% 92draulic )nstitute. T e static water tan':suction c am/er s all a&e two compartments, a&ing a total e%%ecti&e &olume o% a/out 11!!m3, wit pro&isions to isolate one o% t e compartments w ic re;uire repair:maintenance. T e suction c am/ers : static water tan' s all /e pro&ided wit drain and o&er%low connections leading to t e nearest storm water drain. Static water tan' s all /e o% co&ered t2pe wit suita/le pro&isions %or man and e;uipment entr2. 5illing o% ma'e up water into t e static water tan's s all /e automatic /ased on le&els. T e pump ouse s all /e pro&ided wit proper &entilation, electrics, illumination, instrumentation, and oisting and andling e;uipment. T e electrics o% t e pump ouse s all /e designed as per t e speci%ication gi&en in t e rele&ant c apter.
Page 15 of &29
!".!1.2
!".!1.3
!".!1.4
!".!1.5 !".!1."
!".!1.7
T e capacit2 o% t e oisting and andling e;uipment s all /e selected in suc a manner t at it is a/le to andle t e single ea&iest load. Cranes:monorails wit oist s all /e pro&ided as indicated in t e rele&ant c apter. T e pump ouse s all /e designed wit a pro&ision o% suita/le &entilation %acilities. T e details o% &entilation s all /e as per t e write-up o% air conditioning and &entilation descri/ed in rele&ant c apter. T e pump ouse s all /e pro&ided wit necessar2 illumination %acilities. T e details o% illuminations a&e /een gi&en in t e rele&ant c apter. T e sc eme o% ma'e-up water suppl2 s all ensure maintenance o% normal water le&el in t e static water tan' and pre&ent wastage t roug o&er%low. .e&el switc s all /e pro&ided in t e static water tan' w ic will actuate motor:solenoid operated gate &al&e on ma'e-up water line to t e static water tan' in order to maintain water le&el wit in a desired range. 8 /2pass ma'e-up water line wit %loat &al&e s all also /e pro&ided into t e static water tan'. 5ollowing interloc's s all /e pro&ided %or water le&el in t e static water tan' : suction c am/er o% t e %ire water pumps 1. Eer2 low- 8udio &isual alarm * %ire water pumps w ic are wor'ing will trip and no pump will start. 2. .ow- 8udio &isual alarm * motor operated &al&e on t e ma'e up water line opens. 3. 9ig - $otor operated &al&e on t e ma'e up water line closes. 4. Eer2 9ig - 8udio &isual alarm. T e pump ouse s all /e pro&ided wit ade;uate drainage %acilities wit necessar2 side slope, c annels, etc.. Suita/le toe drain, connected to garland drain, s all /e pro&ided in t e pump ouse to drain out an2 spillage o% water %rom t e glands etc. 5inal arrangement s all /e decided /2 t e +urc aser : Consultant during detailed engineering stage on case to case /asis. 8ll t e %ire water pumps s all /e o% ori6ontal, centri%ugal t2pe and s all a&e %looded suction. (ac pump s all /e complete in all respects comprising t e %ollowing= (ac pump s all a&e suction %rom t e inlet eader >w ic is connected to t e %ire water static water tan'?. T e deli&er2 line o% eac pump s all /e connected to t e main eader. T e %ollowing %low &elocities s all /e maintained %or t e pump suction and deli&er2 /ranc es.
!".!1.8
!".!1.9
!".!1.1!
!".!1.11 !".!1.12 !".!1.13
Page 16 of &29
P pe D a#eter Lpto #0 15! mm #0 2!! mm to 45! mm !".!1.14 !".!1.15
S(ct o! s 'e !." to 1.! m:s !.8 to 1.2 m:s
De- /er0 s 'e !.9 to 1.5 m:s 1.2 to 1.5 m:s
(ac pump s all /e pro&ided wit a Gate Eal&e on t e suction side and a non-return &al&e and Gate Eal&e : motori6ed <5 Eal&es on t e deli&er2 side. (ac pump s all /e pro&ided wit local indication o% pressure on suction side and local indication and signaling o% pressure on deli&er2 side (ac eader s all /e pro&ided wit suita/le num/er o% &al&es %or isolating and maintenance purpose. 8ll t e &al&es o% diameter 25! mm and a/o&e and t e &al&es re;uiring remote control operation s all /e electricall2 operated. (lectricall2 operated &al&es s all /e pro&ided wit limit switc es as a sa%et2 measure. (lectricall2 operated &al&es s all a&e pro&ision %or manual operation also. 8ll $anual &al&es o% si6es o% 125mm and a/o&e s all /e gear operated. #ismantling : @u//er (1pansion -oints near t e pumps on /ot suction and deli&er2 lines s all /e pro&ided w ere&er necessar2. T e pipe networ' and &al&es wit in t e pump ouse s all /e ade;uatel2 supported so as to a&oid undue stress on t e pumps. $inimum clear gap to /e 'ept /etween e;uipment to e;uipment : pipe s ould /e 1!!! mm, /etween e;uipment to wall s ould /e 2!!!mm and /etween &al&es to wall s ould /e1!!! mm. )% eig t o% t e e;uipment is more t an 1 m minimum gap s ould /e not less t an t e eig t o% t e e;uipment. T e oists s all /e designed in accordance wit t e latest edition o% )S-3938-1983 standard su/-ect to an2 modi%ications and re;uirements speci%ied in rele&ant c apter. 9oist will /e operated /2 pendant pus /utton station. DESIGN CRITERIA FOR FIRE +ATER PUMPS HORI;ONTAL < &ERTICAL CENTRIFUGAL PUMPS
!".!1.1"
!".!1.17 !".!1.18 !".!1.19
!".!1.2!
)6.* )6.)*.:
!1.+umps pro&ided in t e pump ouse s all /e ori6ontal centri%ugal t2pe wit %looded suction. 8s %ar as practica/le, pumps o% reputed indigenous ma'es s all /e pre%erred. +ump t2pe s all /e 9SC SSS# t2pe onl2.
2009.MECON Limited. All rights reserved TS for Fire Fighting Facilities !ac"age No. 0#$%
Page 17 of &29
!2.T e ori6ontal pumps s all /e mounted on a common /ase plate wit t e motor : diesel engine and s all /e directl2 coupled to t e motor : diesel engine t oroug a %le1i/le coupling wit out an2 gear reducer. !3. T e pumps > ori6ontal as well as &ertical centri%ugal? s all /e designed, manu%actured and tested as per )S=152!-198!, )S=512!-1977 @.8.1991, )S=9137-1978 @.8.1993 or as per international standards accepta/le to t e +urc aser and will /e suita/le %or t e re;uired dut2 conditions and capacities. T e pumps and t eir au1iliar2 e;uipment s all /e suita/le %or t e re;uired dut2 conditions and s all /e designed and constructed %or continuous dut2 at %ull load. 0o negati&e tolerance in t e per%ormance o% t e pump. T e main %ire water pump s all /e capa/le o% suppl2ing not less t an 15!G o% t e rated capacit2 at a ead not less t an "5G o% t e rated ead. T e s ut-o%% ead s all not e1ceed 12!G o% t e rated ead. 5or t e electricall2 dri&en %ire water pump, t e rating o% t e motor s all /e at least e;ui&alent to t e orsepower re;uired to dri&e t e pump at 15!G o% its rated disc arge. $otor ratings s all /e selected wit a deli&er2 &al&e in %ull2 open condition. 5or t e diesel engine dri&en %ire water pump, t e derated orsepower o% t e diesel engine s all /e ig er o% t e %ollowing two &alues= a? 2!G in e1cess o% t e ma1imum orsepower re;uired to dri&e t e pumpset at its dut2 point. /? T e /rea' orsepower re;uired to dri&e t e pumpset at 15!G o% its rated disc arge. !8. T e motor capacit2 s all a&e a margin o&er its <9+ a/sor/ed at t e pump s a%t at dut2 point and t e margin s all /e 25G %or motors o% rating upto 15'4, 2!G %or motors o% rating 18.5'4 to 1"!'4 and 15G %or motors o% rating 2!!'4 and a/o&e. T e a/o&e margin s all /e in addition to temperature derating. T e e;uipment and au1iliaries s all /e designed %or ;uic' and economical maintenance. T e e;uipment s all /e easil2 dismanta/le wit out distur/ing t e suction and deli&er2 pipe connections. T e e;uipment design s all incorporate pro&isions %or reduction in noise le&el. T e rotating elements o% t e pumps s all /e c ec'ed %or critical speed in /ending as well as in torsion. T e critical speeds s all /e at least 3!G awa2 %rom t e normal speeds %or units wit %le1i/le s a%ts and at least 2!G awa2 %rom t e ma1imum operating speed in case o% sti%% s a%ts.
Page 18 of &29
!4.
!5.
!".
!7.
!9.
!1!. !11.
!12. !13. !14.
8ll passages inside t e pump casing and impellers, w ic ma2 /e inaccessi/le to mac ining, s all /e ground to a smoot %inis as %ar as practica/le. T e direction o% rotation s all /e clearl2 mar'ed eit er /2 incorporating it on t e casing or /2 separate metal plate arrow securel2 %itted to t e casing. T e ead 7 Es 7 disc arge c aracteristics o% t e pump s all /e continuousl2 rising %orm t e dut2 point to t e s ut o%% point wit out an2 6one o% insta/ilit2. T e re;uired dut2 range %or a pump s all /e on t e sta/le portion o% its ead capacit2 cur&e close to t e /est e%%icienc2 point. T e ead de&eloped at t e /est e%%icienc2 point s all /e close to t e re;uired di%%erential pressure so t at t rottling is not re;uired at pump disc arge. T e power-Es- disc arge c aracteristics s all /e non-o&erloading t2pe. T e pump s all /e so selected and installed t at t e a&aila/le 0+S9 is not lower t an t e re;uired 0+S9 e&en in t e most ad&erse operating conditions. T e pump s all /e o% pro&en ma'e and design a&ing material o% construction w ic is t e /est o% its 'ind %or t e particular application and s all /e manu%actured using /est engineering practices under strict ;ualit2 control. (ac pump s all /e tested as per t e standards stipulated elsew ere in t is document. T e test s all include 2drostatic test, static and d2namic /alancing tests, per%ormance tests material tests and motor routine tests. T e pump s a%t and /earing s all /e ade;uatel2 si6ed to ta'e t e un/alanced %orced due to mal-operation. T e pump gland s all ensure proper sealing wit out e1cessi&e tig tening o% t e pac'ing. +roper cooling and %lus ing arrangement %or t e gland s all /e pro&ided w ere&er re;uired. 8ll mo&ing parts o% t e pump s all /e ade;uatel2 guarded to pre&ent an2 in-ur2 to operating personnel. +umps s all /e designed and installed 'eeping in &iew t e eas2 accessi/ilit2 o% its parts %or maintenance. 8ll end suction pumps s all /e o% /ac'-pull-out design and s all /e pro&ided wit spacer coupling o% ade;uate lengt . $ec anical seals s all /e pro&ided at all pumps en&isaged %or closed loop circuit. 8n isolating &al&e s all /e pro&ided on t e suction line o% eac pump and anot er isolating &al&e toget er wit a non-return &al&e s all /e pro&ided at t e deli&er2 line o% eac pump. +ressure gauges s all /e pro&ided at t e suction and deli&er2 %lange o% eac pump.
!15. !1".
!17.
!18. !19.
!2!. !21.
Page 19 of &29
!22.
T e suction pipeline s all /e laid at a constant down ward slope %rom pump centre line to t e suction c am/er. @educers used in t e line s all /e eccentric t2pe to 'eep t e top o% t e suction line straig t. (ac pump s all /e pro&ided wit ade;uate sa%et2 interloc's including o&erload and dr2 running protection. #ismantling -oints s all /e pro&ided on t e deli&er2 side o% large si6e pumps to %acilitate ;uic' maintenance, w ere&er re;uired. 8ll pumps s all /e pro&ided wit suita/le li%ting attac ments and eac installation s all a&e suita/le andling %acilities. pump
!23. !24. !25. !2".
8 clear minimum gap o% 1!!! mm s all /e maintained /etween t e pump and t e ad-acent piping, ot er e;uipment or structures %or proper mo&ement. )n case t e eig t o% t e top most part o% t e pump %rom t e wor'ing %loor is more t an 1.! m, t e minimum clearance s all /e increased to 1!!! mm. T e details o% pumps s ould matc wit t e dri&e motors t roug out t e wor'ing li%e o% t ese e;uipments and to meet operational re;uirement. 9ig -speed motors o% 3!!! rpm s all not /e used, as %or as practica/le. 4or'ing our meter s all /e pro&ided on control panels to monitor conditions and su/se;uent ageing : reduced e%%icienc2, etc. Ei/ration readings, etc. o% new installation s all /e supplied. +umps s all /e installed and commissioned as per manu%acturerBs instructions. 8 continuous running %or 72 ours s all /e re;uired /e%ore %inal acceptance is gi&en to t e pumping installation. Design criteria for ri!e !o"ers of #! s a5 Motors
!27.
!28. !29.
06.02.2
Re1er separate chapter 1or the sa#e. 35 ):. D ese- e!" !e Ge!eraSuita/le diesel engine to dri&e t e main %ire water pump s all /e supplied wit all standard accessories. 4 ile rating t e diesel engine, t e site conditions and climatological data o% t e plant as gi&en in t is speci%ication s all /e ta'en into account. T e engine s all /e capa/le o% deli&ering t e rated output continuousl2 >24 ours operation? under t e site conditions indicated earlier.
Page 20 of &29
T e engine s all run steadil2 at an2 load wit in its rated load, as speci%ied in <S=5514-1958. Suita/le automatic go&erning s2stem s all /e pro&ided. T e %uel %or t e engine s all /e ig speed diesel as per )S= 14"!-1974. )*. a? 5uel tan' ' F(e- S(pp-0 S0ste#
T e %uel tan' s all a&e t e capacit2 to store %uel %or 4 ours continuous run at rated output. )t s all /e pro&ided wit le&el gauge cali/rated in litres, %illing in and cleaning and oles, drain coc', sel% supporting %rame * connection %or %uel oil to t e engine %uel oil s2stem. )t s all also /e pro&ided wit a le&el switc to signal oil less t an or e;ual to 3!G o% tan' capacit2. /? 5ilter 8 duple1 %ilter o% suita/le capacit2 to suppl2 %uel oil at rated output. c? 5uel pump
d? 5uel in-ection and control s2stem %or compression ignition. e? )nterconnecting piping. >+lastic piping not allowed? %? ),. 8 and pump o% suita/le capacit2 and su%%icient lengt o% plastic pipe : tu/e s all /e pro&ided %or %illing up t e diesel tan'. Coo- !" S0ste# T e cooling s2stem s all /e designed to cool t e ot parts o% t e engine %or sa%e operation. )t s all utili6e ordinar2 industrial cooling water %or t e cooling s2stem. )t s all incorporate t e %ollowing main e;uipment. a? @adiator= )t s all /e o% su%%icient capacit2 wit %an, guard %or t e %an and s all /e mounted on t e engine %rame wit out re;uiring e1ternal supporting structures. /? 4ater circulation pump c? 4ater %ilter )=. d? T ermostatic control %or /2-passing t e radiator during cold start. L(3r cat o! S0ste# T e lu/rication s2stem /e sel% contained wit t e %ollowing e;uipment
Page 21 of &29
a? Sump= To store su%%icient oil %or circulation, suita/le sump s all /e located in t e engine /? +ump= Suita/le pump %or %orced lu/rication c? 5ilter d? .u/ricating oil cooler . e? )nterconnecting piping
)>.
Start !" s0ste# a? T e engine s all /e capa/le o% /ot automatic and manual start. T e normal mode o% starting is automatic /ut in t e e&ent o% %ailure o% automatic start or at t e discretion o% t e operator, t e engine s all /e capa/le o% /eing started manuall2. /? Since t e %ire water pump dri&en /2 t e diesel engine is not re;uired to run continuousl2 %or long period and t e operation will not /e %re;uent, special %eature s all /e /uilt into t e engine to allow it to start wit in a &er2 s ort period e&en i% it as remained idle %or a considera/le period. c? T e engine s ould /e designed in suc a wa2 t at it s all /e started /2 one operator. )% necessar2, wit out an2 preliminar2 eating o% t e com/ustion c am/er. 8ll controls : mec anisms w ic a&e to /e operated in t e starting process, s all /e wit in eas2 reac o% t e operator. d? 8utomatic cran'ing s all /e e%%ected /2 a /atter2 dri&es 24E #C, motor a&ing ig starting tor;ue to o&ercome %ull engine compression. T e /atter2 s all a&e ade;uate amperes our capacit2 to pro&ide t e starting power %or t e diesel engine. 8 selector switc s all /e pro&ided at t e automatic starting control panel to select manual: auto starting o% t e engine t roug /atter2. (ngine ST8@T:ST3+:T(ST /uttons s all /e pro&ided on control panel. T e automatic starting arrangement s all include, as a sa%eguard, a @epeat Start %eature so t at i% t e pinion o% t e starting motor does not engage t e %l2w eel at t e %irst attempt, it is automaticall2 retraced and a%ter a s ort pause again it will ad&ance towards t e %l2w eel. T is repeat start %eature s all continues until 3 'ic's a%ter w ic t ere will /e suita/le annunciation. T e operator s all /e %ree to operate t e repeat c2cle %eature till t e /atter2 is %ull2 drained. T e /atter2 capacit2 s all /e ade;uate %or ten >1!? consecuti&e starts wit out rec arging wit a cold engine under %ull compression.
Page 22 of &29
e? T e /atter2 s all /e used e1clusi&el2 %or staring t e diesel engine and 'ept %ull2 c arged all t e time. 8rrangement %or /ot tric'le and /oost c arger s all /e pro&ided. 9owe&er, w en t e engine starts running pro&ision s ould /e 'ept to ensure t at t e c arger is automaticall2 disconnected and t e /atter2 is /eing c arged /2 t e engine d2namo. 8t no time s ould t e /atter2 /e disconnected so t at is not a&aila/le to start t e engine. %? T e c arger s all gi&e constant #C output &oltage irrespecti&e o% incoming &oltage &ariation speci%ied. T e c arger s all /e wit %ull2 controlled /ridge circuit wit diodes.
)6.
Go/er! !" S0ste# a? T e engine s ould /e pro&ided wit an ad-usta/le go&ernor capa/le o% regulating engine speed wit in a range o% 1!G /etween s ut-o%% and ma1imum load conditions o% t e pumps. T e go&ernor s all /e set to maintain rated pump speed at ma1imum pump load. /? T e go&ernor s all /e capa/le o% operating wit out e1ternal power suppl2.
)?.
A r !ta8e T e air inta'e s2stem s all ensure su%%icient clean air to t e engine. )t s all incorporate t e %ollowing items=a? Suction air %ilter= t is s all /e o% oil /at t2pe to suppl2 clean air to t e engine.
)@.
E7ha(st T e ot e1 aust gases s all /e let-o%% wit suita/le e1 aust s2stem. 8ll t e ot parts located at t e wor'ing le&el s all /e insulated T e e1 aust s2stem s all includes= a? (1 aust mani%old /? Silencer= T e e1 aust gases s all /e let-o%% t roug suita/le silencer. Su%%icient lengt o% straig t pipe s all /e pro&ided a%ter t e e1 aust silencer to lea&e t e gases at su%%icient eig t a/o&e t e engine and outside t e room.
Page 23 of &29
c? (1pansion -oint )A. Fo(!'at o! 1ra#e Suita/le %oundation %rame >common wit pump and control panel? wit %oundation /olts * nuts. ):). )::. Co(p- !" a!' Co(p- !" "(ar' I!str(#e!ts
T e e;uipment s all /e pro&ided wit necessar2 instruments to c ec' t e wor'ing o% t e engine continuousl2. T e %ollowing instruments s all /e pro&ided and t e same s all /e %i1ed on a common instrumentation panel mounted directl2 on t e engine. a? .u/ricating oil temperature indicator /? .u/ricating oil pressure indicator c? Cooling water inlet temperature indicator d? Cooling water outlet temperature indicator e? Speed-cum- our-meter T e pressure and temperature gauges s all /e o% pre%erred ma'e. T e %ollowing protection: annunciation also s all /e pro&ided. a? 9ig cooling water outlet temperature /? .ow lu/ricating oil pressure c? (ngine o&erspeed alarm 8n2 ot er instrument, control and protection e;uipment re;uired %or t e sa%e operation o% t e engine s all also /e pro&ided. )6.)*., !1. ;ualit2. Shop test !" o1 p(#ps 8ll materials, casting and %orging s all /e o% tested
Page 24 of &29
!2.
+ump casing s all /e o% ro/ust construction and 2drostaticall2 tested at 2!!G o% t e rated pressure or 15! G s ut o%% pressure, w ic e&er is ig er. T e test pressure s all /e maintained %or at least 15 minutes. T e impellers along wit an2 ot er un-mac ined rotating parts s all /e tested %or proper /alancing in order to a&oid undue &i/ration during operation. +er%ormance tests s all /e carried on eac centri%ugal pump. +er%ormance test s all /e made to determine t e %ollowing. a? /? c? d? T e disc arge against a speci%ied ead w en running at a speci%ied speed under a speci%ic suction ead. T e power a/sor/ed /2 t e pump at t e s a%t ><9+? under t e a/o&especi%ied conditions. (%%icienc2 o% t e pump under t e a/o&e speci%ied conditions. Eariation o% re;uired 0+S9 wit disc arge.
!3.
!4.
!5. !".
T e pump accessories li'e /earings, couplings etc. s all /e su/-ect to s op tests as per manu%acturerBs standards. T e materials o% construction o% &arious components o% all e;uipment and material co&ered under t e scope o% is speci%ication s all /e certi%ied /2 t e tenderer wit regard to t eir compliance to speci%ications laid down %or t em under rele&ant clauses o% applica/le standards and :or t e manu%acturing drawings o% t e tenderer dul2 appro&ed /2 t e purc aser. 5ormal material test certi%icates to t e e%%ect s all /e issued /2 t e tenderer. 8ll test results and certi%icates including material test certi%icates s all /e su/mitted %or appro&al to t e purc aser /e%ore dispatc o% e;uipment. 8 stainless steel name plate s all /e %urnis ed and securel2 attac ed /2 stainless steel pins at an easil2 accessi/le point on t e pump. T e plate s all /e stamped wit t e %ollowing minimum in%ormation= 0ame o% $anu%acturer $odel 0o. +urc aserMs item no. or tag 0o. Serial num/er o% pump
Page 25 of &29
!7.
!8.
Capacit2 in cu/ic meters per our +umping ead in meters o% li;uid column Speci%ic gra&it2 o% li;uid pumped @e&olutions per minute +ump input power, '4 $otor rating, '4 #esign code )S:)+SS=
)6.)*.= A5
Mater a- o1 co!str(ct o! 1or p(#ps Hor Bo!ta- p(#ps= S$. No a? /? c? d? e? %? g? ? i? -? '? l? m? n? o? p? ITE% Casing )mpeller S a%t S a%t slee&e 4earing rings S ims * pac'ings 0ec' ring .antern ring Gland <earing end co&er <earing 9ousing Coupling +ump * motor N3B rings Slee&e nuts Cowl nuts <ase plate %ATERIAL C) )S= 21! 5G2"! C58$ (n8 SS41! C) 5G 22! <rass )S= 442 C) 5G 2"! C) 5G 22! C) 5G 22! C) 5G 22! C) 5G 22! C) 5G 2"! 0itrile @u//er SS 41! SS41! $S 5a/ricated
&'
&ert ca- p(#ps 4 1or 'ra !a"e s0ste# 5.

Page 26 of &29
S-.No. 1 2 3 4 5 " 7 8 9 !".3 !".!3.1
ITEM )mpeller Casing Casing ring S a%t S a%t slee&e Gland <ase %rame Companion %langes Column pipe
MATERIAL C8ST )@30 >)S 21! 5G 2"!? C8ST )@30 >)S 21! 5G 2"!? C8ST )@30 >)S 21! 5G 2"!? (0 8 SS 7 41! C8ST )@30 >)S 21! 5G 2!!? $.S 58<@)C8T(# $.S )S=2!"2Gr < $.S
DESIGN CRITERIA FOR PIPE +OR% T e term pipe wor' re%erred erein generall2 co&er pipes, %ittings >suc as /ends, tees, reducers, plugs, nipples, soc'ets, unions, %langes, crosses etc.?., &al&es o% &arious t2pes and %unctions >suc as gate, glo/e /utter%l2, /all, c ec', diap ragm, electricall2 operated, pressure reducing &al&es, etc.? strainers, %ilters, oses, ose couplings ose clamps, ose no66les, %ire 2drant assem/lies, pipe supports, corrosion protection etc. +ipe wor' is intended to con&e2 water. T e pipe wor' s all /e designed, manu%actured, assem/led and tested as per t e latest standards, codes and recommendations o% t e <ureau o% )ndian Standards, 80S), 8ST$, 8448, or ot er e;ui&alent international standards. +ipe wor' s all /e complete in all respects including all accessories essential %or proper installation, operation and maintenance, e&en t oug suc items are not speci%icall2 mentioned in t e speci%ication. +iping s2stem s all /e designed wit ig degree o% relia/ilit2 so t at t e s2stems per%orm t e dut2 o% %luid andling wit out an2 %ailure under all conditions o% plant operation. +iping la2out must %ollow good engineering practice. +roper attention s all /e gi&en to o/tain %ull %unctional re;uirement o% t e piping s2stem wit a la2out w ic pro&ides su%%icient clearance %or ot er e;uipment and operating personnel, eas2 access %or operation and maintenance, con&enient supporting points and neat appearance. Complete design o% piping s2stem s all /e su/-ect to appro&al /2 t e 3wner: Consultant. T e design s all ta'e into account t e e%%ect o% internal:e1ternal pressure, t ermal e1pansion, sel% weig t o% piping, support reactions, surge and water ammer,
Page 27 of &29
!".!3.2 !".!3.3
!".!3.4
!".!3.5
!".!3." !".!3.7
eart ;ua'e and wind e%%ects at site, corrosion and erosion etc. and an2 ot er e%%ects dictated /2 good engineering practices. !".!3.8 T e %ollowing &elocities s all /e adopted %or si6ing pipe wor', unless ot erwise speci%ied in tec nical speci%ication Lpto #015!mm O 1.! 7 1.2 m:s #0 2!! to #045!mm O 1.2 7 1.8 m:s (ac eader s all /e pro&ided wit suita/le num/er o% &al&es %or isolating and maintenance purpose. T e +iping s2stems s all not impose undue %orces on e;uipment terminals. $ild steel : Car/on steel pipelines s all /e used in general %or water suppl2 %acilities. 8s %ar as possi/le all t e pipelines s all /e laid toget er along t e piping corridor. T e piping corridor s all /e parallel to and /2 t e side o% roads. T e entire pipe networ' s all /e pro&ided wit manuall2 operated &al&es %or isolation:controlling purpose. Eal&es %or si6e 125 mm and a/o&e and /e gear operated and &al&es o% si6e a/o&e 25! mm s all /e electricall2 operated. +ipeline passing under or t roug e;uipment %oundations or walls o% /uildings or an2 ot er inaccessi/le structure s all /e pro&ided wit steel encasing pipes %or eas2 insertion and remo&al. Continuous welding $S pipes s all /e used %or water suppl2 %acilities. (1cept w ere ot erwise speci%ied, all piping s all a&e /utt welded connections wit a minimum o% %langed -oints %or connections to e;uipment. <ranc es s all in general, /e %ormed /2 welding. +ro&ision s all /e made %or /ranc es %or cleaning and %lus ing o% pipelines w ere&er necessar2. Eal&es pro&ided on t e o&er-ground pipe networ' s all /e pro&ided wit structural plat%orms and access ladders. steel
!".!3.9
!".!3.1! !".!3.11 !".!3.12
!".!3.13 !".!3.14
!".!3.15 !".!3.1" !".!3.17
+ro&ision s all /e made %or support o% piping w ic ma2 /e disconnected during maintenance wor'. 8ll large pipes and all long pipes s all a&e at least two supports eac arranged in suc a wa2 t at an2 lengt o% piping or &al&e ma2 /e remo&ed wit out an2 additional supports /eing re;uired. +ipe supports s all /e capa/le o% supporting t e pipelines under all conditions o% operation.
Page 28 of &29
!".!3.18
!".!3.19
8ll t e /uried pipelines s all /e laid as %ar as possi/le at a dept o% a/out 12!! mm, /elow %inis ed ground le&el >i.e. t e top o% t e pipelines s all /e 1.2 m /elow t e %inis ed ground le&el?. )solation :control &al&es drain &al&es, air release &al&e pro&ided on t e /uried pipe networ' s all /e oused in suita/l2 si6ed co&ered @CC &al&e pit wit remo&a/le co&er o% cast iron : pre cast @CC and t e &al&e pits s all /e o% sel% draining t2pe. 8ir release &al&es s all /e pro&ided at t e ig est points o% eac sector o% t e pipeline and drainage &al&es s all /e pro&ided at t e lowest points o% eac sector o% t e pipeline. 4 ere&er t e /uried pipelines are crossing t e roads and railwa2 trac's, t e2 s all /e suita/l2 encased wit mild steel pipes or rein%orced concrete casing pipes >as per )S=458-1988 class 0+3 %or road crossings * 0+4 %or railwa2 trac's crossings? and t e di%%erent si6es o% t e encasing pipes s all /e as gi&en /elow=
!".!3.2!
!".!3.21
Encase( (ia!eter ()to &00 &+0 200 *00 *+0 ,00 +00 -00 $00 #00 900 &000 !".!3.22
i e Encasing i e ) *or Encasing i e )for *$ange( i e' si+e ,e$(e( i e' si+e )!!' )!!' *00 ,00 +00 -00 -00 $00 #00 900 &000 &&00 &200 &,00 2+0 *00 ,00 ,00 +00 -00 $00 #00 900 &000 &&00 &200
$ec anical cleaning and anticorrosi&e protection o% underground $S pipelines s all con%orm to )S= 1!221 7 1982. T e anticorrosi&e protection o% pipelines s all consist o% t e %ollowing acti&ities in se;uence. i? 8pplication o% one coat o% coal tar primer ii? 8pplication o% one coat o% coal tar enamel
Page 29 of &29
iii?
3ne wrap o% %i/er glass tissue
i&?8pplication o% one coat o% coal tar enamel &? 3ne la2er o% %i/erglass tissue impregnated in coal tar enamel. &i?8pplication o% t e %inal coat o% a water-resistant w ite was . 8lternati&el2 Coal tar /ased anticorrosion tape as per )S= 15337 7 2!!3 s all /e pro&ided %or protection o% underground mild steel pipelines. T e t ic'ness o% tapes s all /e 3 mm upto pipe diameter #0 3!! mm and 4 mm a/o&e pipe diameter o% #0 3!! mm.
)6.),.*, 8? 1. 2. 3. 4. <? 1. 2. 3. 4. C? 1. 2. #? 1. 2. 3.
PIPE SPECIFICATION <lac' +ipes #0 15 to #0 5!= (nd condition Class $aterial $anu%acturing = <e&el (nds = Sc edule 8! = 8ST$.8.53 Gr=<:)S=1239 >+art-)? 199! 7 9ea&2 class = Seamless : 8s per applica/le )ndian Standards
Car/on Steel +ipes #0 "5 to #015! as per )S=1239-199!>@.8.-2!!4? = (nd condition Class $aterial T ic'ness = <e&el (nds = 9ea&2 = 8s per )S= 1387 : )S 1239 - 199! >+art-)? 9ea&2 = 8s per )S= 1239, 9ea&2.
+ipes a/o&e #0 15! as per )S=3589-2!!1= (nd condition = <e&eled ends %or /utt welding $aterial = Car/on steel, Gr. 5e 41! Car/on Steel G.) >Gal&anised )ron? +ipes #0 15 to #0 15! as per )S= 1239-+art-)2!!4= (nd condition = Screwed up to #0 5!, <e&eled ends %or all t e si6es a/o&e #0 5!. Grade = 9ea&2 $aterial = Car/on steel, Gr. 5e 41!
Page 30 of &29
(?
T ic'ness o% pipe s all /e as per )S=1239 +art-), 9ea&2 %or #015! and /elow and )S=3589 %or #02!! and a/o&e and s all /e selected as gi&en /elow= #02!!, #025!, #03!! #035!, #04!!, #045! #05!!, #0"!! O".35 mm O7.14mm O7.925mm.
5? G?
$itre /end s all /e used in t e pipes o% si6e #01!! and a/o&e. $itre /ends are to /e made %rom t e parent pipe. @ead2 made %ittings are to /e used %or t e pipes o% si6e #08! and /elow. #imensional tolerance and (nd 5inis es Tolerance on outside diameter o% t e pipe and speci%ied t ic'ness s all con%orm to t e limits laid down in )S=3589-2!!1. 5inis pipe s all not de&iate %rom straig tness /2 more t an !.2G o% t e total lengt . +ipes to /e /utt welded s all /e supplied wit ends /e&eled to an angle o% 3! degrees >I 5 degree 7 ! degree? measured %rom a line drawn perpendicular to t e a1is o% t e pipe. T e root %ace s all /e 1." P !.8 mm. TABLE FOR MACIMUM SPAN OF SUPPORTS No# !a- p pe s Be 4##5 25 4! 5! "5 8! 1!! 15! 2!! 25! 3!! 35! 4!! Ma7 #(# spa! 1or - 9( ' ser/ ces 4#5 2.! 3.! 3.! 3.5 4.! 4.5 5.! ".! ".5 7.! 7.5 8.!
)6.),.*=
Page 31 of &29
Note. Eertical pipe wor' s all /e clamped at inter&als o% 3.5m >appro1.? and at t e /ase o% eac riser. $a1imum span at t e place o% turning s all /e !.7 times o% normal span. 06.0-.2. !1. LA$ING BURIED PIPELINES 8ll /uried pipelines s all /e laid wit eart co&er su%%icient to a&oid damage %rom pressure o% &i/ration caused /2 t e sur%ace tra%%ic. $inimum eart co&ering o&er t e pipe s all /e 12!! mm %rom t e %inis ed ground le&els. 5or la2ing o% /uried pipelines eart wor' in e1ca&ation, /ac' %illing and acceptance o% trenc es etc. s all /e as per )S= 5822-1994 and )S= 3114-1994 and )S= 12288-1987. T e trenc s all /e so dug t at t e pipe line can /e laid to t e re;uired alignment and at t e re;uired dept , proper le&eling o% t e e1ca&ated sur%aces is an essential re;uirement. )n case stones, /oulders etc. are %ound at t e /ottom o% t e trenc w ic can not /e remo&ed completel2, t e /ottom s all /e le&eled /2 sand la2er %or a minimum t ic'ness o% 15! mm. )% t e dept o% e1ca&ation is more, proper protection %or side walls s all /e pro&ided till t e pipe le&eling is completed. T e entire pipe trenc es /ottom s all /e co&ered wit local sand /ed o% 5! mm t ic' la2er. 8%ter la2ing t e pipelines, 15! mm t ic' la2er o% local sand s all /e pro&ided o&er t e sand /ed. +recautions s all /e ta'en at all t e times to pre&ent damage to t e coating and wrapping in t e pipe lines and appurtenances as applica/le /2 wor'men or trespassers during la2ing or at an2 ot er time. +ipe andling slung and an2 /loc'ing used in andling or storing t e pipes must /e well padded to a&oid damage to pipe and its coating. 8%ter la2ing a pipeline on s'ids it s all /e t oroug l2 cleaned, inspected and %or an2 damage to t e protecti&e coating, satis%actor2 repair wor' s all /e per%ormed w ile t e pipe is suspended a/o&e t e trenc . <e%ore la2ing t e pipelines, t e trenc es s all /e e1amined /2 t e 3wner and a%ter is appro&al onl2 t e pipes can /e laid.
!2.
!3.
!4. !5. !". !7.
!8.
!9.
Page 32 of &29
!1!.
8%ter t e pipes are erected and tested, t e /ac' %illing o% t e trenc es s all /e done wit loose soil %ree %rom stones, /ric's and metallic pieces, in la2ers and s all /e well rammed and compacted. Metho' o1 D(a- t0 Co!tro- ! +e-'e' Eo !ts 5ollowing steps s all /e ta'en /2 t e Tenderer, /esides controlling ;ualit2 in general, to ma'e e%%ecti&e control in carr2ing out welded -oints. 4elding procedures s all /e prepared in line wit )S= 73!7 >+art 7 )? 7 1974, rea%%irmed in 1991 and tests s all /e carried out to ;ualit2 procedures. 0um/er o% procedures will depend on &aria/les li'e positions o% welding, t ic'ness range etc. 3nce a welding procedure is ;uali%ied, strict ad erence to it s all /e made during actual welding. 4elders emplo2ed s all /e ;uali%ied as per )S= 731! >+art 7 )? 7 1974, rea%%irmed in 1987 a%ter passing necessar2 tests. 4elding consuma/les s all /e o% appro&ed t2pe. Suc consuma/les are, owe&er, su/-ect to ;uali%2ing initial c ec' tests as per )S= 814-1991. T e Tenderer s all strictl2 %ollow appro&ed welding procedures during actual welding. <esides, t e %ollowing stages o% inspection s all also /e carried out= i? 4eld edge preparation /e%ore welding, proper %it up, position o% welding, cleaning o% slag /etween t e passes, proper weld pro%ile etc., s all /e c ec'ed &isuall2 amongst ot ers. ii? 0on-destructi&e tests o% weld o% welded -oints s all /e carried out as per appro&ed procedures: drawings.
)6.),.*6 !1. a?
/? c? d?
06.0-.2/ !1.
Preparat o! o1 Eo !ts T e Tenderer s all prepare t e edge correctl2 to t e s ape, si6e and dimensions o% t e &ee-groo&es as per 80S) <-1".25 unless ot erwise speci%ied in drawings: documents. T e welding sur%aces s all /e smoot , uni%orm and %ree %rom %ins, tears, notc es or an2 ot er de%ect w ic ma2 ad&ersel2 a%%ect welding and s all /e %ree %rom loose scale, slag, rust, grease, paint, moisture or an2 ot er %oreign material. T e clean sur%ace s all e1tend to a/out 1! mm /e2ond t e welding %aces to a&oid contamination o% t e weld metal wit %oreign material and to a&oid unsound weld deposit.
Page 33 of &29
!2.
)6.),.*@ !1.
Asse#3-0, A- "!#e!t < +e-' !" T e se;uence o% welding s all /e so planned and %ollowed t at t ere s all /e a /alance o% welding a/out t e neutral a1is o% t e %a/rication. T e Tenderer s all emplo2 su%%icient num/er o% welders wor'ing at t e same time in diagonal ;uadrants o% t e s ell using /ac'-step met od o% welding. T e rate o% progress o% eac welder s all /e more or less e;ual and ;ualit2 uni%orm. T e general direction o% welding s all /e towards t e %ree end o% t e -oint, /ut in a long -oint as in s ell %a/rication, /ac'-step tec ni;ue s all /e used to reduce distortion. To minimi6e internal loc'ed up stresses due to welding, t e &ertical -oints %or t e s ell s all /e welded and completed to a circular course and t en t e ori6ontal circum%erential seam welded. 9owe&er, /e%ore t e welding o% ori6ontal seam started, t e complete circular course s all /e aligned and ad-usted %or t eir correct a1es. 8lternati&el2, t e Tenderer s all complete eac course in all respect on ground and t en t e pre-assem/led course s all /e listed and placed in position. )n suc a se;uence and planning, t e same principle o% /alancing o% weld a/out t e neutral a1is s all /e %ollowed and t e met od o% %a/rication o% eac course s all /e similar to %a/rication o% penstoc' pipes o% transmission: industrial pipelines o% /igger diameter. +ipe and attac ment s all /e aligned properl2 /2 accurate and permanent met ods prior to welding. )% tac' welds are used, t e tac' s all /e eit er %used into t e %irst la2er or weld or else c ipped out. Tests o! 2e-'e' Fo !ts Eisual e1amination T e Tenderer s all conduct &isual e1amination and measurement o% e1ternal dimensions o% t e weld %or all -oints. <e%ore e1amining t e welded -oints, areas close to it on /ot sides o% t e weld %or a widt not less t at 2! mm s all /e cleared o% slag and ot er impurities. (1amination s all /e done /2 magni%2ing glass w ic as a magni%ication power o% ten >1!? and measuring instrument w ic as an accurac2 o% P !.1 mm o% /2 weld gauges. 4elded -oints s all /e e1amined %rom /ot sides. T e Tenderer s all e1amine t e %ollowing during t e Eisual e1amination= ii? iii? C ec' t e correctness o% s ape and si6e o% t e welded -oints )ncomplete penetration o% weld metal
Page 34 of &29
!2.
!3.
!4.
!5.
)6.),.*A >a?
i&? &? &i? &ii? &iii? i1? 1? 1i?
)n%lu1 <urns Lnder cuts Ln-welded crates Crac's in welded spots and eat a%%ected 6ones +orosit2 in welds and spot welds Compression in welded -oints as a result o% electrode impact w ile carr2ing out contact welding #isplacement o% welded element.
T e Tenderer s all carr2out an2 or all tests as speci%ied ereina%ter to satis%2 t e +urc aser a/out t e accepta/ilit2 o% t e welded -oints, as directed /2 t e +urc aser. >/? .i;uid #2e-penetrant Test .i;uid d2e-penetrant tests s all /e carried out in accordance wit )S= 3"58-1981, rea%%irmed in 1991 %or sur%ace: su/-sur%ace de%ects. >c? Test /2 <lowing T e sur%ace o% t e weld s all /e co&ered wit soap solution consisting o% one >1? litre o% water and undred >1!!? grams o% soap. Compressed air s all /e /lown %rom t e opposite side at pressure o% 4 to 5 'g:cm 2. T e distance /etween t e tip o% /ase and t e weld s all not /e more t an 5! mm. 8n2 %ormation o% soap /u//le will indicate welding de%ects. +orta/le compressor s all /e arranged /2 t e Tenderer, i% necessar2, %or t is purpose. )6.),.,) To-era!ce #e&iations %or assem/l2 o% welded -oints ma2 /e permitted to t e %ollowing e1tent= S$. No. a% Source /utt-Foints i? Gap /etween t e ends o% plates To$erance %an#a$ arc . 2.00 mm / &.00 mm A#to!atic 0 &.00 mm
Page 35 of &29
S$. No. ii? Stepping o% one plate o&er t e ot er Single Eee-groo&e Foints i? <e&el angle ii? Gap /etween two iii? Stepping o% plate o&er ot er .ap Foint i? 3&erlap ii? Gap /etween sur%ace Tee-%iller Foints i? Gap /etween edges o% t e we/ t e sur%ace o% %lange one
To$erance %an#a$ arc &.00 mm A#to!atic 2.00 mm
1%
0 + deg. . 2.00 mm / &.00 mm 2.00 mm +.00 mm 2.00 mm 2.00 mm
0 + deg. . &.00 mm 2.00 mm +.00 mm &.00 mm 2.00 mm
c%
t e t e and t e
d%
)6.= !1.
DESIGN CRITERIA FOR &AL&ES. 5low control : isolating &al&es, drain &al&es, air release &al&es and Compensators, w ere&er necessar2, s all /e pro&ided %or t e complete in-s op pipe networ'. 8ll &al&es s all /e suita/le %or ser&ice conditions i.e. ;ualit2 o% %luid, %low temperature and pressure under w ic t e2 are re;uired to operate. Eal&es s all /e pro&ided on pipe networ' %or isolation o% pipe section and e;uipment, control o% pressure and %low, &enting, draining etc. T e2 s all /e suita/le located considering ease o% operation and maintenance. 8ll &al&es s all /e pro&ided wit and w eel and position indictor. T e %ace o% eac and w eel s all /e clearl2 mar'ed wit words C3penD and CS utD wit arrows ad-acent to indicate t e direction o% rotation.
Page 36 of &29
!2. !3.
!4.
!5.
Eal&es s all /e pro&ided wit suita/le e1tension spindle and ead stoc' assem/l2 w ere&er re;uired. )n case gears or /e&el s2stem are used , t ese s all /e o% cast steel or suita/le grade cast iron wit mac ine cut teet . 0on-return &al&es s all a&e a permanent C8rrowD inscription on its /od2 to indicate direction o% %low. .arger si6e &al&es s all /e pro&ided wit arrangement. /2 pass and drain
!". !7. !8. !9. )6.)=.:
5loat operated &al&e s all /e pre%era/l2 /e rig t angled pattern complete wit /all %loat, le&el and ot er accessories. <utter%l2 &al&es s all /e o% ;uota/le %langed, tig t s ut o% design wit angular tra&el o% 9! deg. %rom open to s ut o%% position. Spec 1 cat o! 1or /a-/es 1. <utter%l2 &al&es s Lpto "50< 8!0< and a/o&e 2!!0< and a/o&e all /e O O O 4a%er t2pe, #ou/le %langed, Gear operated >wit sel% loc'ing at an2 position?. .i%t c ec', #ou/le %langed, swing c ec' &al&e. Gear operated.
2. C ec' &al&es s all /e Lpto 4!0< O 5!0< and a/o&e O 3. Sluice &al&es s all /e 1250< and a/o&e O A5 1 2 3 4 5 " 7 8 9
Spec 1 cat o! 1or "-o3e /a-/e T2pe <od2 * <onnet Glo/e &al&e %or water suppl2 pipelines G$ to )S = 318-1981,>@8M91?Gr .T< 7 2, C.). 4edge G$ to )S = 318-1981>@8M91? Gr .T< 7 2, C.). Stem Stainless steel <ac' seat G$ to )S = 318-1981>@8M91? Gr .T<-2 Seating sur%ace * rings G$ to )S = 318-1981>@8M91? Gr .T<-2 9and w eel Cast )ron to )S=21!-1993 Gr. 5G-2!! Gland, Gland plate disc 0on %errous allo2 spindle nut Gland +ac'ing 8s/estos )S=2712-1979
Page 37 of &29
1! 11 12 13 14
+ressure rating $anu%acturing standard $a1. operating temp 3peration (nd connection
15
92dro static testing
+0 O 1." 0:mm2 )S=778-1984 >@8 2!!5?:)S=781-1984 5! deg C $anuall2 operated and w eel wit open and close direction indication. Screwed upto 4! mm e1cept ot erwise mentioned. 5langed ends %or 5! mm * a/o&e, )S="392-1971 >@8-1988?, ta/le 17 S ell test O 15 'g:cm2 Seat test O 1! 'g:cm2 <ac' seat test O 1! 'g:cm2 1- 8rrow indicating %low direction 2-(m/ossed name plate gi&ing details o% tag no., t2pe * si6e 4ater
1"
Special %eatures re;uired
17 B5
Ser&ice
Spec 1 cat o! 1or 3(tter1-0 /a-/es Ma!(a- Operat o! G P!e(#at c Operat o!GMotor Operate' 1 2 3 4 5 " 7 8 9 1! 11 12 13 14 15 1" T2pe <od2 * Co&er #isc Seat, <od2:#isc +in Spindle <olting, internal <olting, e1ternal (nd connections +ressure rating $anu%acturing Standard 92dro static testing Test certi%icates Ser&ice $a1. operating temp T2pe o% operation 5langed t2pe <utter%l2 &al&e %or water suppl2 pipe lines. C), )S= 21! 5G 2"! SS, )S= 3444-1987, Gr ": 7 (+#$: 0eoprene Stainless Steel, 8)S)-41! SS, )S= ""!3-72, 15 Cr 1" 0i 2 SS Car/on Steel, >9T? 5langed +0 O 1." 0:mm2 )S-13!95-1991:8448=C-5!4: <S=5155: )+SS-1-!"-!12 : 8+) "!9 <od2=24 'g:cm2 Seat=1" 'g:cm2 @e;uired %or material: 2dro test 4ater 1!! #eg !C Lpto #0125- .e&er operated
Page 38 of &29
<e2ond #0125- Gear operated $anual : +neumatic>8s and w ere speci%icall2 mentioned? Re#ar8s- 8ll &al&es a/o&e #0"!! s all /e supplied wit SS 3!4 gas'ets wit C85 %illers 17 3peration C5 Spec 1 cat o! 1or s-( ce /a-/es Ma!(a- Operat o! G P!e(#at c Operat o!GMotor Operate' 1 2 3 4 5 " 7 8 9 1! 11 12 13 14 15 1" 17 18 19 2! D' T2pe <od2 * Co&er #isc 9andw eel +in Stem Gas'ets Gland pac'ing Gear Gear ousing +inion * pinion s a%t (nd connections +ressure rating $anu%acturing Standard 92dro static testing Test certi%icates Ser&ice $a1. operating temp T2pe o% operation 3peration @ising spindle t2pe sluice &al&es %or water wor's C), )S= 21! 5G 2"! C), )S= 21! 5G 2"! C), )S= 21! 5G 2"! Stainless Steel, 8)S)-41! SS, )S= ""!3, 12 Cr 13 !4 Cr 18 0i 1! 0eoprene ru//er @u//er 8llo2 Steel, )S= 157!, 4!0i2Cr1$328Gr < Cast Steel, )S= 1!3!, 23!-45! 4 SS, )S= ""!3 5langed +0 O 1." 0:mm2 )S-1484"-2!!! <od2=24 'g:cm2 Seat=1" 'g:cm2 @e;uired %or material: 2dro test 4ater 1!! #eg !C Lpto #01!!- $anual <e2ond #0125 - Gear operated $anual : +neumatic>8s and w ere speci%icall2 mentioned?
Spec 1 cat o! 1or CI G Bro!Be P-(" /a-/es 1 T2pe #0 "5 and a/o&e= C.). Two wa2, lu/ricated t2pe, tapered plug = Si6es up-to #05!= <ron6e, T port 3 wa2 lu/ricated t2pe tapered plug
Page 39 of &29
2 3 4 5 " 7 8 9
<od2, Gland +lug
Co&er * C) as per )S=21!-1993 5G 22! C) as per )S=21!-1993 5G 22!: <ron6e as per )S=318 .T<-2 <lac' 9e1agonal /olt wit nut as per )S=13"4 +art 1 * 3,1992, class 4.":4 @u//eri6ed 8s/estos C85 Screwed end up-to #05!, 0+T: 5langed end %or #0"5 * a/o&e as per )S= "392-1971 >@8M88? wit matc ing %langes, ta/le-17. +0 O 1." 0:mm2 <S 5353:8+) 599
5asteners Gland +ac'ing Gas'ets (nd connection
+ressure rating $anu%acturing Standard 1! 92dro static <od2=24 'g:cm2 testing Seat=1" 'g:cm2 11 Test certi%icates @e;uired %or material: 2dro test 12 Ser&ice water 13 $a1. operating 5! !C temp 14 Gear arrangement 4orm gear o% C.S.:%orged steel 0ote= 1. T2pe o% t reading %or screwed end will /e as per )S=554-1999. 2. +lug &al&e o% si6e #02!! s all /e pro&ided wit worm gear arrangement.
E'
Spec 1 cat o! 1or Ba-- /a-/e G F(-- 3ore G * +A$ G , +A$ 1 2 3 4 5 " 7 8 9 1! T2pe <od2, Co&er * Gland <all Stem 5asteners Gland +ac'ing (nd connection +ressure rating $anu%acturing Standard Test certi%icates t ree piece, @educed /ore, %loating /all, +T5( seated CS as per 8ST$ 821" 4C< SS , 8ST$ 8 351, Gr. C5 8$ 8)S) 31" 9T, SS 3!4 onl2 35G Car/on 5illed +T5(: Grap ite Soc'et welded : 5langed > @e%er #etailed Eal&e .ist? +0 O 1." 0:mm2 <S 5353:8+) 599 @e;uired %or material: 2dro test
Page 40 of &29
11
5or instrument %itting, air &ent and %or regulation purposes. 12 $a1. operating temp 1!! #eg !C 13? @emar's- Soc'et weld connection wit nipple pipe o% 1!!mm welded on all openings *' Spec 1 cat o! 1or A r Re-ease /a-/e 8ir release &al&es s all /e cast iron, single large ori%ice t2pe, wit %langed ends. 8ir release &al&e s all con%orm to )S= 14845-2!!!. 1 T2pe 8ir release &al&es s all /e cast iron, t2pe S1 * S2 upto diameter 5! mm and t2pe #S1 a/o&e diameter 5! mm and upto diameter 2!! mm )S= 14845-2!!!. C) 5G 21! as per )S=21! Gun metal )S=318 .T<-2 Tim/er core wit &ulcanite: ru//er coating Gun metal )S=318 .T<-2 SS, )S= ""!3, !4Cr17 Gun metal )S=318 .T<-2 Car/on steel )S=13"7 C) 5G 2!! as per )S=21! Grap ite as/estos: -ute: emp Gun metal )S=318 .T<-2 Compressed as/estos 5i/er 3 mm t ic' Eulcanite (/onite Screwed up-to #04! and %langed %or #05! * a/o&e +0 1." 0:mm2 <od2 = 24 'g:cm2 Seat = 1" 'g:cm2 Test duration = 3! minutes
Ser&ice
2 3 3 4 5 " 7 8 9 1! 11 12 13 14 15
<od2 <od2 seat ring 5loat #isc Stem #isc nut <olts:studs, nuts Gland Gland pac'ing 8ir release nipple Gas'et @u//er /all (nd connection +ressure rating Test pressure
G'
Spec 1 cat o! 1or co#pa! o! F-a!"es 1 2 T2pe #imensional Standard @aised %ace plate %langes, Slip-on, welded, plate %a/ricated, mac ined %inis . 8s per )S-"392-1971>@8M88?, +0O1." :1.! 0:mm2 as per &al&e rating, Ta/le-17:11, drilled o%% centre, @5.
Page 41 of &29
$aterial C.S as per )S-2!"2 -1992 G@.8. 0ote= Eal&e %langes and matc ing %langes s all /e drilled as per )S="392-1971 >@8M1988?, ta/le 17 %or +0 1.".
H'
Spec 1 cat o! o1 act(ator 1or #otor Be' /a-/e 1 2 3 4 $a'e 3utput motion 3peration time Ser&ice condition @otor' : 8utor' : 8uma : .imitor;ue : 8ppro&ed @otar2 9! sec. >$a1.? )nlet +r.O8.5 Hg:cm2 >$a1?: as per S2stem re;uirement )nlet Temp.O4! deg.C ma1. 5luid O 4ater 8ctuator s all /e supplied complete wit t e %ollowing= 9andw eel %or manual operation +osition indicator 3pen : close limit switc es Tor;ue limit switc es (ac limit switc s all a&e 2 03 : 2 0C Contact switc %or 1! 8$+. at 24! E $otor terminals and limit switc contacts s all /e wired upto a terminal /o1 to /e mounted on t e &al&e actuator
5 a / c d e %
I'
Motor spec 1 cat o!s 1 2 3 4 5 " 7 8 9 1! $a'e * T2pe Suppl2 Conditions Control Eoltage +rotection (nclosure #ut2 Condition Class o% )nsulation 0o. o% Starts: r 8llowed #esign +er%ormance <rea'down Tor;ue 0)0. +@(5(@@(# $8H( * 3 +98S(,4 4)@(, SAL)@@(. C8G(, )0#LCT)30 $3T3@ 415 E 8C I 1!G, 5! C:S I 3G -"G 24! E )+-54 T(5C S2, 3! $)0LT(S Q5M Temperature rise limited to class-< "! 8s per )S=325-199" $inimum 2.5 T5. or ig er
Page 42 of &29
0'
Spec 1 cat o! 1or Cast stee- chec8 /a-/e 1 2 3 4 5 " 7 8 9 1! 11 12 13 14 15 1" 17 18 T2pe <od2 #isc Stop +in 9inge pin Spring @etainer <od2 <earing (2e <olt <od2 Seal #isc Seal <od2 Test +ressure Seat Test +ressure #esign Standard #imensions Testing Special %eatures re;uired (nd Connections C ec' Eal&e 8ST$ 8 21" Grade 4C< 8ST$ 8 351 Gr. C58 $ >SS 31"? 8)S) SS 41! 8)S) SS 41! )0C300(. C58$ >SS 31"? 8)S) SS 31" Car/on Steel (+#$ )ntegral 45! psi >g? 32! psi >g? >$a1.? : 285 psi >g? >$in? 8+) 594 8s per 8+) 594 8s per 8+) 598 1. 8rrow indicating t e %low direction. 2.(m/ossed name plate gi&ing details o% tag 0o. si6e, etc. 5langed
1'
Spec 1 cat o! 1or Cast Iro! s2 !" chec8 /a-/e 1 2 3 4 5 " 7 8 T2pe <od2, co&er, door, /earing older 9inge pin, door pin, door suspension pin <earing /rus es : /earing /loc' #oor %ace ring, seat ring +lugs %or ing pin : air release plug <olts 0uts Swing C ec' Eal&e C) )S=21! 5G2"! 8)S) SS 41! <ron6e )S=318 .T<-2 8)S) SS 31" 8)S) SS 31" CS )S=13"3>+art-1? cl 4." CS )S=13"3>+art-3? cl 4.!
Page 43 of &29
9 1! 11 12 13 14 15 1" 17 L'
Gas'ets 9inge <od2 Test +ressure Seat Test +ressure #esign Standard #imensions Testing Special %eatures re;uired (nd Connections
C85 )S=2712 C) )S=21! 5G2"! 45! psi >g? 32! psi >g? >$a1.? : 285 psi >g? >$in? )S=5312 )S=5312 8s per <S=5153 1. 8rrow indicating t e %low direction. 2.(m/ossed name plate gi&ing details o% tag 0o. si6e, etc. 5langed
Spec 1 cat o! 1or 3a-- 1-oat /a-/e 1 2 3 4 Single - /eat t2pe wit /alancing piston
)6.> )6.)>.:
<od2:Co&er:Gland:+iston Cast iron Gr 2!! as per )S 21!-1993 Seat ring:&al&e guide )S 318 Gr 2 +ilot &al&e seat:%ace )S 318 Gr 2 cap:spindle 5 .in's $.S. cadmium plated " 5ace ring:piston cups .eat er 7 .e&er $.S. 8 5loat Tinned copper 9 +ressure rating +0 O 1 0:mm2 1! (nd connections 8s per )S= 554:<S+ T read. 11 92drostatic testing <od2 - 15 Hg:cm2 12 Ser&ice 5ire water . DESIGN CRITERIA FOR RUBBER ECPANSION G DISMANTLING EOINTS. Mater a- spec 1 cat o!. @u//er (1pansion Foints s all /e made o% ig grade a/rasi&e resistant natural ru//er compound rein%orced wit ade;uate num/ers o% piles o% ea&2 cotton duc', ra2on cord, impregnated wit in ru//er compound and %urt er rein%orced wit s;uare metal ring em/edded in it. T e outer e1posed sur%ace o% ru//er e1pansion -oints s all /e gi&en a coating o% s2nt etic:neoprene ru//er and %urt er painted wit c lorinated ru//er /ased paint. @u//er e1pansion -oints will /e suita/le %or design temperature o% 5!! C and %or andling clear water. @u//er e1pansion -oints s all a/sor/ &i/ration, s oc' and a1ial compression o% 1! mm, a1ial elongation o% 1! mm and lateral mo&ement o% 1! mm. Co!tro- (! t.
Page 44 of &29
)6.)>.*
3ne set o% control unit >stretc er /olt assem/l2? consisting o% 2:3 nos. limit rod >material )S=3"57 Gr. "."?, Stretc er <olt, Triangular +late >material )S=22"?, 0uts >material )S=13"3 Gr. ".3? Steel 4as er and @u//er 4as er o% durometer ardness o% 1!!deg Centigrade I:- 5 deg Centigrade. T e control unit s all /e made suita/le to ma'e @( -oint and no. o% limit rod matc ed against eac . )6.)>., TECHNICAL PARAMETERS OF RUBBER ECPANSION G DISMANTLING EOINT 1. S-. No 1 2 2. Test pressure $a1. +ressure >operating? #esign pressure <urst pressure .ea' test .engt Tie rod S Be #0 #0 Dt0
= 18 'g:cm2 or as per rele&ant standards = 12 'g:cm2 = 1" 'g:cm2 = 4 times design pressure >Guaranteed? = 18 /ar>g?, -oint s all /e 'ept immersed in water /at to c ec' lea' tig tness
3. 4. 5. ".
= 8s per rele&ant Standard = 3 tie rods per @u//er (1pansion Foint
$aterial o% construction <od2 = 0atural ru//er compound Co&er = 0eoprene ru//er Tie rod = Car/on steel #esign temperature (nd connection = 0ormal 4! #eg Centigrade $a1 8! #eg. Centigrade >4orst Case? = Car/on steel %orged loose %langes at /ot ends, wit dimensions as per )S= "392 SPECIFICATION EDUIPMENTS FOR FIRE FIGHTING
7. 8. )6.6
a? .anding &al&e : 2ard 2drant s all /e as per )S= 529!-1993, T2pe-8 i.e. single outlet t2pe and s ould a&e T8C appro&al. (ac landing &al&e s all consists o% &al&e, matc ing %lange, C85 gas'et, nuts, /olts, instantaneous spring loc' t2pe
Page 45 of &29
%emale outlets wit /lan' cap * c ain. (ac 2drant s all a&e a permanent stainless steel name plate and stainless steel tag %i1ed on t e 2drant indicating t e tag no.. 92drants s all /e designed %or 1!!G tig t s ut o%%. $aterial o% construction %or t e &arious component s all /e as %ollows=/ <od2, <onnet, Stop &al&e, C ec' nut = .T< 2 >)S=318-1981?: SS. 5emale coupling and /lan' cap = SS !4Cr 170i $o2 as per )S="529-1972. 9andw eel = C) as per )S= 21!-1978. 3t er components= as per )S= 529!-1993. /? T e ose ca/inet s all /e %a/ricated out o% 18 S4G $.S. s eet. T e si6e o% t e ca/inet s all /e suita/le %or olding one no. 3!m long ose or two oses o% 15m oses and s all /e anging t2pe %or indoor installation * supporting t2pe on pedestals %or out door installations. T e two sides and /ac' o% t e ose ca/inet s all /e made %rom s eet /2 pressing. T e top s all a&e pressed edges slig tl2 pro-ecting outside to pre&ent water >w ile cleaning etc? %rom entering t e ca/inet. T e ca/inet s all /e %itted wit one door a&ing glass pane. T e t ic'ness o% glass s all not /e less t an 3mm. T e door s all /e pro&ided wit a 'no/ and a loc' wit duplicated 'e2 on t e /od2 o% t e door. T e glass o% t e 'e2 /o1 s all /e easil2 replacea/le. Suita/le oo's, etc. s all /e pro&ided in t e ca/inet to old t e ose reels etc. Suita/le wall mounting /rac'et s all /e pro&ided wit t e ca/inet. T e word Q'e2M s all /e painted >on t e /od2 o% door? wit an arrow pointing t e glass o% 'e2 co&er. T e ose ca/inet s all /e painted red %rom outside and w ite %rom inside. c% (ac ose s all /e as per )S="3"-1988 T2pe-8 * o% rein%orced, ru//eri6ed %a/ric lined can&as material and s all /e supplied complete wit instantaneous spring loc' t2pe coupling as per )S=9!3-1993. (ac ose s all a&e a diameter o% "3mm and lengt o% 15m %or internal 2drants and 3!m %or 2ard 2drants. (ac no66le s all /e o% 25mm si6e. 2mm G) wire s all /e wound around t e coupling so as to co&er 12!mm lengt o% ose. 0o66le, coupler >male:%emale?, li%ting 'e2 s all /e o% stainless steel construction.
Page 46 of &29
A!!e7(re I to Chapter > . C-ar 1 e' +ater D(a- t0 SNo. 1. 2. 3. 4. 5. ". 7. 8. 9. 1!. 11. 12. 13. 14. 15. 1". Para#eter Total suspended solids p9 Total 8l'alinit2 Tur/idit2 Colour 3dour Taste Calcium as NCaB $agnesium as N$gB 8luminium as 8l )ron as N5eB C loride as NClB 5louride as 5 Sulp ate as NS34B 0itrate as 033 @esidual %ree c lorine U! t mg:l FTL mg:l, ma1 0TL 9a6en,ma1. mg:l -do-do-do-do-do-do-do-do.ess t an 35 ".5 to8.5 "5 5 5 Lno/-ectiona/le 8greea/le 75 3!, ma1. !.!3,ma1. !.3 25! 1.! 2!! 45 !.2
Page 47 of &29
)?.) )?.:
Ho st !" a!' Ha!'- !" Fac - t0 Scope o1 +or8 T e scope o% wor' o% t e Tenderer co&ers design, engineering, manu%acture: %a/rication, inspection, assem/l2, s op testing, painting, pac'ing, %orwarding, dispatc , suppl2 and transportation to site, site storage, preser&ation, erection, testing and commissioning o% t e crane complete wit electrical e;uipment, standard accessories and attac ments to /e installed as co&ered under t is speci%ication. Suita/le capacit2 Single Girder (lectric Lnder Slung Cranes s all /e pro&ided in t e +ump 9ouse. Crane capacit2, span and its oo' approac s all /e suita/le %or maintenance o% all t e e;uipment: single ea&iest part o% e;uipment o% more t an 2!! 'g in weig t wit in t e +ump 9ouse. #ut2 classi%ication o% single girder under slung crane s all /e class-)) indoor >$5 as per )S=3177-1999 * )S=8!7197"?. 9eig t o% li%t o% Crane will /e suc t at t e crane oo' can reac t e /ottom most %loor o% t e /uilding. T e span o% t e crane and its oo' approac s all /e suita/le %or maintenance o% all ea&2 e;uipment wit in t e /uilding and dut2 classi%ication o% t e same will /e as mentioned under clause no. !7.!1.!1. T e scope o% wor' o% t e tenderer s all also include suppl2 o% t e %ollowing= i? Suppl2 o% +#<, isolating switc es wit enclosure, #S. along wit %i1ing accessories. ii? T e tenderer s all include in t eir scope o% suppl2 spares re;uired %or success%ul commissioning o% t e cranes as listed /elow. 9owe&er, T e Tenderer ma2 also indicate t e commissioning spares %or eac crane recommended /2 t em o&er and a/o&e t e list o% spares mentioned /elow %or proper commissioning o% t e e;uipment= L st o1 Co## ss o! !" Spares 1or Cra!e 5 Mecha! ca- . S-. Ite# No. 1 3il Seals and gas'ets %or all gear /o1es. 5 E-ectr ca- . S-. Ite# No. 1 )ndicating .amp wit 9older
!7.!1.1
!7.!1.2
!7.!1.3
Dt0. 3ne set eac
Dt0. 1 0o. eac t2pe

Page 48 of &29
+ower contactor a? Contactor Contacts /? Coil %or power contactor 1 set eac t2pe 1 0o. eac t2pe 1 set eac t2pe 1 0o. eac t2pe 1 0o. eac t2pe 5G o% eac rating 1!G o% eac total ;uantit2 1 0o. 1 0o. eac
8u1iliar2 Contactor a? Contactor contacts /? Coil %or au1. contactor
4 5 " 7 8
+us <utton +ower 5uses Control 5uses Control Switc es <ra'e Coil
iii? T e %ollowing is t e list o% mandator2 spares re;uired %or 2 2ears normal operation: maintenance o% t e crane. T e Tenderer ma2 indicate mandator2 spares as recommended /2 t em o&er and a/o&e t ese items. T e spare part list s all /e su/mitted along wit t e o%%er. T e Tenderer s all ;uote )tem wise price %or t ese spares. 9owe&er, t e list o% spares will /e %inali6ed a%ter discussion wit t e success%ul tenderer. L st o1 Ma!'ator0 Spares 1or * $ears Operat o! 5 Mecha! caS-. Ite# Dt0. No. 1 5irst reduction pinion s a%t wit /earing assem/l2 1 0o. %or all dri&es 2 <ra'e drum %or all dri&es 1 0o. eac 3 <ra'e lining wit ri&ets %or all /ra'es. " +airs eac 5 E-ectr ca- . S-. Ite# Dt0. No. 1 +ower Circuit a? 5i1ed and mo&ing contacts %or stator power 1 set %or eac t2pe contactor /? Contact set %or au1iliar2 contactors 1 set %or eac t2pe c? Coils %or stator power contactors
2 0os. %or eac t2pe

Page 49 of &29
2 3 4
d? Coils %or au1. Contactors e? 3&er load rela2 %? Timers g? 8u1. Contactors $aster controller mo&ing contacts * %i1ed contacts .imit switc es %i1ed * mo&ing contacts $CC<: 5uses %or= a? +ower circuit %uses /? +ower circuit /ase c? Control $C<s: %uses d? Control %use /ase )ndicating lamp wit older Contact element set %or pus /uttons @esistors +unc ed stainless steel #C recti%ier along wit control panel and /ra'e
1 0o. %or eac t2pe 1 0o. %or eac t2pe 2 nos. 1 0o. %or eac t2pe 25 G %or eac mec anism 25 G %or eac mec anism 18 0os. 1! 0os. 4 0os. 1 0o. 2 0os. 1 set 1 0o. grid %or eac current rating $in. 1 no. %or eac si6e 1 0o. o% eac t2pe
5 " 7 8
9 Coils: T ruster unit %or /ra'es o% eac t2pe i&? Suppl2 o% %ollowing )nsurance Spares. i? $otor %or eac 'w raring ii? #C (lectro $agnetic /ra'e wit recti%ier panel and resistance
1 no. 1 no. o% eac si6e
&? )nitial re;uirement %or oils, lu/ricants and cleaning %luids %or crane including replenis ment during erection, testing and commissioning o% t e e;uipment s all /e included in t e Scope o% Suppl2 o% t e success%ul Tenderer %ree o% cost. &i? Suppl2 o% tools and tac'les re;uired %or maintenance o% t e e;uipment. .ist o% suc tools and tac'les s all /e %urnis ed along wit t e tender. T e price o% t e same s all /e included in t e price o% t e crane itsel%. &ii? Suppl2 o% drawings and documents as per clause no. !7.!3.!3. &iii? <oug t out items s all /e %rom t e appro&ed ma'es onl2. i1? 9oist control panel >T+0 as well as control panel? s all /e located at 1.5m %rom t e wor'ing %loor le&el. 1? Cranes s all /e pro&ided wit centrali6ed lu/rication s2stem.
Page 50 of &29
)?.* )?.)*.: i?. ii?.
Des "! Bas sGCr ter a S !"-e G r'er U!'er s-(!" Cra!e Single Girder Lnder Slung Crane s all /e designed and supplied in accordance wit )S= 8!7-197" and latest re&ision o% )S= 3177-1999. (lectric oists o% Single Girder Lnder Slung Cranes s all /e designed and supplied in accordance wit )S= 3938-1983. )n electric oist /loc', oist motor and oist /ra'e s all /e o% %oot mounted t2pe and C.T. motor s all /e o% 5lange mounted t2pe wit disc /ra'e and modular in construction. Single Girder Lnder Slung Cranes s all /e pendant operated. +ower suppl2 to t e Single Girder Lnder Slung Crane s all /e t roug down s op leads >#S.? and s all /e included in t e scope o% t e suppl2 Tenderer. +ower suppl2 to t e oists and C.T. o% Single Girder Lnder Slung Cranes s all /e t roug 5le1i/le Trailing Ca/le. I!str(ct o!s to Te!'erer Tenders s all /e accompanied wit general arrangement drawing %or crane and andling attac ment, i% an2. G. 8. drawing o% crane s all s ow to scale t e ele&ation, side &iew and plan o% t e crane along wit in%ormation suc as clearances, construction o% /ridge structure, oo' approac es, li%t, location o% operatorMs ca/in wit direction o% &iew o% operator: pendant pus /utton station, w eel /ase, w eel loads, w eel diameters, o&er /u%%er dimension, /u%%er eig t, .T and CT /u%%er compressions, motor ratings, speeds, arrangement and disposition o% all t e dri&es and ot er e;uipment installed on t e crane, speed-tor;ue c aracteristics %or eac motion etc. and dul2 %illed up ;uestionnaire to ena/le t e +urc aser to assess t e important tec nical %eatures o% t e e;uipment o%%ered. Tenders ma2 /e re-ected i% compliance wit t is clause is not ensured w ile tendering. T e tenderer s all also clearl2 speci%2 an2 re;uest %or de&iation %rom Tec nical Speci%ication on particular item. Generali6ed statements li'e Rt e crane s all /e manu%actured as per ).S. Standard, our speci%ication etc.R ma2 result in re-ection o% Tenders. Tenderer s all su/mit a time /ar c art along wit t e Tender indicating starting and completion dates o% eac acti&it2, sc edule o% erection, testing and commissioning and testing o% t e cranes.
iii?. i&?. &?. )?., !7.!3.1
!7.!3.2
Page 51 of &29
!7.!3.3
5ollowing drawings s all /e su/mitted in ade;uate num/er o% copies as per GCC %or crane to t e +urc aser: is Consultant in stages %or appro&al : re%erence wit in t ree mont s o% issue o% .etter o% )ntent and prior to commencement o% %a/rication. T e +urc aser : Consultant s all send t eir comments wit in stipulated time o% receipt o% t e drawing. 9owe&er, appro&al o% drawings /2 t e +urc aser will not relie&e t e Supplier o% is responsi/ilities %or correctness, ade;uac2 o% t e design and completeness o% is wor' as per t e contract. 8ll t e drawings and documents will /e in (nglis .anguage. #rawings s all /e complete in all respect wit dimensions, item lists etc. T e general arrangement drawing o% crane containing all in%ormation as descri/ed in earlier paragrap !7.!3.!1 >%or appro&al?. 8ssem/l2 drawing o% indi&idual dri&es li'e oists, long tra&el, cross tra&el etc. >%or re%erence?. .a2out o% ca/in s owing t e location and %i1ing o% all t e e;uipment inside it suc as controllers:operatorMs seat, protecti&e panel, isolating and control switc es, %ire e1tinguis ers, e1 aust and circulating %ans, air conditioners etc. >%or appro&al?. Structural calculations %or girder end carriage and connection /etween t e two >%or re%erence?. $otor power calculation >%or re%erence?. .u/rication arrangement %or t e complete crane >%or re%erence?. )n addition to t e a/o&e, t e +urc aser: Consultant ma2 as' %or su/mission o% ot er drawings, documents, structural, mec anical and electrical calculations o% t e crane %or scrutin2 and re%erence, i% re;uired. T e Supplier s all su/mit material test certi%icates %or structural steel and mec anical components suc as couplings, gear /o1es, rope drums, pulle2s, s a%ts, gears, oo's, w eels etc.
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!7.!3.5
T e Tenderer : Supplier s all ensure t at t e crane s all /e manu%actured as per t e tolerances speci%ied /elow = >i? >ii? Span o&er .T w eels 4 eel /ase .T CT #i%%erence in diagonal .T CT .ong tra&el w eel alignment Tilt o% w eels or /alancer a1le = I " mm upto 4! metres I 5 mm I 3 mm
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I 5 mm I 3 mm >i&? I 1 mm >&? I 1 mm:1!!! mm >9ori6ontal * Eertical? >&i? Trolle2 w eel gauge I 3 mm upto 75!! mm span I 5 mm a/o&e 75!! mm span >&ii? Trolle2 trac' gauge I 3 mm upto 75!! mm span I 5 mm a/o&e 75!! mm span >&iii? #i%%erence in eig t /etween trolle2 rails >9? in relation to t e trolle2 trac' gauge >S?s all /e wit in t e %ollowing tolerances= QSM >mm? Q9M >mm? Lpto 25!! 4 8/o&e 25!! and upto 45!! " 8/o&e 45!! 1! >i1? 9ori6ontal /end o% girder in Span : 2!!! plan >1? S i%t o% t e we/ plates o% 9 : 2!! main * end girders %rom &ertical o&er eig t Q9B measured near t e mid span * close to t e main diap ragm. >1i? Twist o% t e main girder Span : 15!! 81is o% t e %lange plates %rom t e a1is o% t e /eam >1iii? Tolerances on cam/er Lpto 4 mm
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8/o&e 4 mm and upto 8 mm. 8/o&e 8 mm and upto 1" mm. 8/o&e 1" mm and upto 31.5 mm 8/o&e 31.5 mm and upto "3 mm
>I? 5 >-? ! >I? ".3 >-? ! >I? 8 >-? ! >I? 1! >-? !
>1iii? 3&er /u%%er lengt >3&er /u%%er dimension on two sides s all /e same? >1i&? 9eig t o% center o% /u%%er >%rom top o% trac' rail? !7.!3."
I 5 mm I 5 mm
T e Tenderer s all ensure t at minimum amount o% assem/l2 at site is necessar2 %or earl2 commissioning o% t e crane a%ter deli&er2. Site welding and ri&eting s all /e a&oided as %ar as possi/le. T e Supplier, /e%ore proceeding wit design details s all satis%2 imsel% a/out t e site conditions so as to a&oid an2 di%%icult2 in erection, arising out o% design. T e crane s all /e completel2 assem/led and tested in t e SupplierMs wor's %or %ull load and 25 G o&erload on oisting and cross tra&erse motion, in presence o% +urc aserMs representati&e in addition to ot er tests as speci%ied in )S=3177- 1999. T e crane s all /e load tested at site. 5or t is necessar2 sling and load s all /e arranged /2 t e contractor. The cra!e a1ter erect o! at s te sha-- 3e teste' as 1o--o2s = )nsulation tests and ot er tests mentioned in )S= 3177-1999 s all /e carried out. #e%lection Test= T e de%lection test o% t e /ridge girders s all /e carried out as per )S= 3177-1999 8%ter t e de%lection test wit sa%e wor'ing load, t e crane s all /e tested %or de%lection wit 25G o&erload and t ere s all not /e an2 permanent set a%ter t e remo&al o% t e load. Speed Tests = a? 8ll motion o% t e crane s all /e tested wit rated load on all notc es at t e time o% commissioning o% t e crane at site and t e speeds s all /e attained wit in t e tolerance limit.
!7.!3.7
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/? 8ll motions o% t e crane s all /e tested wit 25G o&er load in w ic case t e speci%ied speeds need not /e attained /ut t e crane s all s ow itsel% capa/le o% dealing wit t e o&erload wit out di%%icult2. <ra'e Tests = a? T e oist /ra'es s all /e capa/le o% /ra'ing t e mo&ement wit rated as well as o&erload. 9owe&er, t e /ra'ing pat wit rated load s all not e1ceed oisting speed:12! %or class 2 dut2 cranes. /? T e long tra&el and cross tra&el /ra'es s all /e capa/le o% arresting t e motion wit in a distance in meters e;ual to 1!G o% t e speed in meters:min. and t e retardation due to /ra'ing s all not e1ceed t e &alues as gi&en in t e ta/le /elow= 4or'ing condition @etardation, according to percentage num/er o% dri&ing w eels, >in m:sec2? 1!! 5! 25 !.9 !.45 !.25 1.5 !.75 !.4!
3utdoor >4 en O !.12? )ndoor >4 en O !.2?
!7.!3.9 !7.!3.1! !7.!3.11
.egend O 5riction 5actor #imension o% all +arts used on crane s all con%orm to metric standards. 8ll t e e;uipment s all /e o% reputed ma'e and pro&en ;ualit2 wit regard to t eir per%ormance. T e ma'e s all /e as per appro&ed list o% +urc aser:Consultant. T e crane s all /e inspected and tested during di%%erent stages o% its manu%acture >starting %rom raw materials till t e completion o% t e crane? /2 t e +urc aser: is aut ori6ed representati&e at t e SupplierMs or is su/-supplierMs wor's as per t e inspection procedure mutuall2 agreed /etween t e +urc aser or is aut ori6ed representati&e and t e Supplier. )nspection s all /e regarded as a c ec' up and s all /e in no wa2 /inding on t e +urc aser. #ocuments %or all electrical and mec anical e;uipment supplied wit t e crane s all /e put up %or inspection along wit t e e;uipment. 8%ter inspection, an endorsement would /e made in t e inspection certi%icate a/out t e a&aila/ilit2 o% t e documents.
!7.!3.12 !7.!3.13
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PAINTING 8ll parts o% t e crane s all /e t oroug l2 cleaned o% all loose mill scales, rust or %oreign matter and t en painted as speci%ied. 8ll +arts o% t e crane >e1cept motors, resistors, gears, t rusters etc.? s all /e painted at s op wit one primer coat o% +EC copol2mer al'2d resin wit red-o1ide 6inc c romate. )nterior o% all gear ousing s all /e painted wit oil resistant paint. 8ll mac ine pads, /earing sur%aces on structure or ousing s all /e painted wit w ite lead. 8ll parts inaccessi/le a%ter assem/l2 s all /e painted /e%ore and assem/led w ile paint is still wet. 8%ter erection t e damaged portion o% t e painted sur%aces s all /e retouc ed and t en one intermediate coat o% +EC copol2mer al'2d resin s all /e applied. T e colour s all /e as per c oice o% t e +urc aser. )n case t e crane is su/-ected to corrosi&e atmosp ere, t e intermediate coat o% +EC copol2mer al'2d resin wit micaceous iron o1ide >$)3? s all /e applied. Su/se;uentl2 one %inal coat o% paint o% +EC copol2mer al'2d wit weat er resistant pigment >appro&ed /2 +urc aser? and gloss2 %inis s all /e applied. T e detail o% t e dr2 %ilm t ic'ness >#5T? o% t e di%%erent coats s all /e as %ollows= >a? +rimar2 coat = 3!-4! micron per coat. >/? )ntermediate coat = 7!-8! micron per coat >c? 5inal coat = 4!-5! micron per coat 5or parts e1posed to eat /e2ond 8!! C and upto 15!! C 6inc et 2l silicate primer s all /e used %ollowed /2 a coat o% ig /uild epo12 pol2amide enamel. T e /u%%er and oo' /loc' o% t e crane s all /e painted wit lemon 2ellow /ase and 1!! mm wide /lac' 6e/ra strips at a gap o% 1!! mm. Colour sc eme s all /e as appro&ed /2 t e +urc aser.
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Tech! ca- Spec 1 cat o! o1 S !"-e G r'er U!'er s-(!" Cra!e GENERAL Single Girder Lnder Slung Cranes s all /e designed and supplied in accordance wit )S= 8!7-197" and latest re&ision o% )S= 3177-1999. (lectric oists o% Single Girder Lnder Slung Cranes s all /e designed and supplied in accordance wit )S= 3938-1983. )n electric oist /loc', oist motor and oist /ra'e s all /e o% %oot mounted t2pe and C.T. motor s all /e o% 5lange mounted t2pe wit disc /ra'e and modular in construction. T e crane components s all /e standardi6ed to 'eep t e num/er o% spares to t e minimum. 8ll parts re;uiring replacement or inspection or lu/rication s all /e easil2 accessi/le wit out t e need %or dismantling o% ot er e;uipment or structures. 8ll electrical ca/les s all /e so laid t at t e2 are not lia/le to /e damaged and can /e easil2 inspected and maintained and w en necessar2 an2 damaged ca/le can /e accessed * replaced indi&iduall2. 8ll components %or cranes o% identical capacit2 and dut2 s all /e interc angea/le. Cranes o% t e same capacit2 and dut2 s all /e identical in all respect unless ot erwise re;uired. 0o cast iron parts s all /e used e1cept %or electrical e;uipment and no wood or ot er com/usti/le material s all /e used unless speci%icall2 mentioned ot erwise. #e&iations, i% an2, to t is clause s all /e permitted onl2 wit t e speci%ic appro&al o% t e +urc aser. 8ll mac iner2 or e;uipment included under t is speci%ication must /e e;uipped wit sa%et2 de&ices and clearances to compl2 wit recogni6ed standards and +urc aserMs re;uirements along wit sa%et2 codes and statutes pre&alent at t e place o% installation o% t e e;uipment. 5or welded construction suc as t at o% /ridge girders, end-carriages, rope drums, gear-/o1es etc. steel s all /e as per )S = 2!"2-1992 ;ualit2. 5or welding t ese mem/ers low 2drogen electrodes s all /e used.
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8ll w eels, couplings, open gears etc. s all /e pro&ided wit co&ers, opening on strong inges. 8ll ea&2 co&ers s all /e pro&ided wit inspection windows. 4 ere down s op leads are located /elow runwa2 rails, guards s all /e pro&ided on t e crane to pre&ent t e oist ropes %rom coming in contact wit down s op leads. 8ll /olts e1cept t ose wit n2lon nuts s all /e pro&ided wit grip loc' nuts or spring was ers. 5or outdoor cranes all electrical and mec anical e;uipment w ic are e1posed to weat er s all /e completel2 co&ered or made weat er proo%. T e co&ers s all /e segmental to %acilitate eas2 dismantling and assem/l2. T e end-carriages s all /e %itted wit su/stantial sa%et2 stops to pre&ent t e crane %rom %alling more t an 25 mm in t e e&ent o% /rea'age o% a trac' w eel, /ogie or a1le. T ese stops s all not inter%ere wit t e remo&al o% w eels. 5asteners %or pedestal /loc's, motors, gear-/o1es etc. s all /e easil2 remo&a/le %rom t e top. Studs or /od2 /ound /olts s all not /e used as %asteners %or mec anical items e1cept %or %i1ing co&er. +ower * control ca/les s all /e clamped in-groups separatel2. 8ll trailing ca/les s all /e clamped wit +EC or non-metallic clamps. Group de-rating %actor s all /e appropriatel2 ta'en according to t e recommendations o% t e ca/le manu%acturers /ased on t e met od o% la2ing and num/er o% ca/les /eing laid toget er. Guards o% appro&ed design, w ic will pus %orward o%% t e trac', an2 o/-ect placed across it, s all /e attac ed to eac end o% t e end carriages. +arts o% steel %rames carr2ing mac iner2 s all /e pro&ided wit dou/ling plates o% ade;uate t ic'ness ri&eted or welded and mac ined to true sur%ace. #e%ects in t e material li'e %ractures, crac's, /low oles, lamination, pitting etc. are not allowed. @ecti%ication o% an2 suc %law is permissi/le onl2 wit t e appro&al o% t e +urc aser. STRUCTURAL DETAILS .
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T e crane /ridges s all /e o% welded dou/le we/ /o1 construction and s all /e designed as per )S= 8!7-197" and:or 8)S( 03. ". T e materials o% construction s all /e welda/le mild steel in compliance wit t e rele&ant standard. 9owe&er, ig strengt welda/le structural steel also ma2 /e used w ere&er re;uired in compliance wit t e rele&ant standards.
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T e crane /ridge girder upto 12-m span s all /e in one piece. Girders a/o&e 12 m span ma2 /e spliced. T e num/er o% suc splices s all not e1ceed 2 upto 3" m span. <e2ond 3" m span, t e num/er o% splices ma2 /e 3. Splices s all /e designed to resist all t e %orces and moments to w ic it is su/-ected to, plus 5!G t ereo%. 9owe&er, in no case t e strengt de&eloped /2 t e splice s all /e less t an 5!G o% t e e%%ecti&e strengt o% t e material. Splices s all /e proportioned and arranged so t at t e gra&it2 a1is o% t e splice is in line wit t e gra&it2 a1is o% t e mem/ers -oined so as to a&oid eccentricit2 o% t e loading.
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<lac' /olts s all not /e used in t e main structure o% t e cranes. Cross tra&el rail s all /e %i1ed to t e /ridge girders /2 clamping onl2 and not /2 welding. Trans&erse %illet welding on load carr2ing mem/ers s all /e a&oided. 8ll /utt welds on tensile 6one s all /e S-ra2ed. +lates, /ars, angles and w ere practica/le ot er rolled sections used in t e load /earing mem/ers o% structures s all not /e less t an " mm in t ic'ness. T e end-carriages s all /e o% dou/le we/ plate /o1 construction and s all /e connected to t e girders /2 welding at s op or /2 large gusset plates and %itted /olts to ensure ma1imum rigidit2. #rop stops and -ac'ing pads s all /e /uilt-in %eatures o% t e cranes. 5ull lengt c ec'ered plate plat%orms s all /e pro&ided along /ot sides o% t e cranes in order to ensure eas2 access to crane cra/, long tra&el gears and ot er parts. Sa%et2 railings s all /e pro&ided on crane /ridges and cra/ %rame. 8ccess to t e operatorMs ca/in s all /e &ia staircases onl2 and not t roug ladders. +lat%orms to %acilitate inspection and dismantling o% long tra&el w eels and main current collectors s all /e pro&ided. T e cra/ %rame s all /e made o% steel plates and rolled sections in welded construction. Cra/ %rame s all /e %a/ricated in one piece i% t ere are no transport limitations. )% t e trolle2 is %a/ricated in more t an one piece due to transport limitation, t e design o% t e splice s all /e suc t at one unit o% mec anism mounted on one part o% t e trolle2, does not come o&er t e ot er part. 5oot-wal's s all /e o% su%%icient widt to gi&e at least 5!! mm clear passage at all points e1cept /etween railing and /ridge girder w ere t is clearance ma2 /e reduced to not less t an 44! mm.
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T e plat%orms along t e /ridge girders and o&er t e cra/ s all allow con&enient access %or replacement, inspection, lu/rication etc. %or di%%erent mec anical and electrical components. T e minimum t ic'ness o% c ec'ered plates s all /e " mm 3:+ %or indoor cranes * 8 mm 3:+ %or outdoor cranes. MECHANICALG ELECTRICAL EDUIPMENT DETAILS . Rope 'r(#s @ope drums s all /e o% cast steel or %a/ricated out o% rolled steel plates. 5a/ricated drums s all /e stress relie&ed /e%ore mac ining. T e groo&es o% t e drum s all /e smoot %inis ed. @ope drum s all /e %langed at /ot ends. Rope shea/es @ope s ea&es s all /e o% cast steel or %a/ricated out o% rolled steel plates. + re ropes T e wire rope s all /e emp cored %or all cranes. @opes s all /e regular rig t and la2 as per )S = 22""-1989. T e construction o% t e ropes s all /e " 1 37 upto 1" mm diameter and " 1 3" a/o&e 1" mm diameter. Hoo8 < Hoo8 3-oc8 T e 9oo' s all /e single s an' swi&eling t2pe as per )S= 155"!-2!!5. T e s ea&es s all /e %ull2 encased in closed %itting guards %a/ricated out o% steel plates. Smoot opening s all /e pro&ided in t e guards to allow t e %ree mo&ement o% rope, and oles s all /e pro&ided %or drainage o% t e oil. Gears < "ear-3o7es Straig t and elical spur gearing s all /e used %or all motions. 4orm * /e&el gearing ma2 /e used in e1ceptional cases wit t e speci%ic appro&al o% t e +urc aser. 8ll %irst reduction gears s all a&e elical teet . 8ll pinions s all /e integral wit t e s a%t. 8ll gears s all /e ardened and tempered allo2 steel a&ing metric module. 3&er ung gears s all not /e used. Sur%ace ardness %or pinion s all /e 255 to 3!! <90 and %or gears it s all /e 215 to 2"! <90. #i%%erence in ardness o% pinion and gear s all not /e less t an 2! <90. 8ll cast steel gear s all /e tested /2 Gamma @a2. 8ll gears s all /e enclosed in oil tig t gear-/o1es. Gear/o1es s all /e o% ig grade cast iron:cast steel or %a/ricated and split at eac s a%t centerlines. 5a/ricated gear/o1es s all /e stress relie&ed /e%ore mac ining. 5or Cross-tra&el and .ong-tra&el motions, &ertical gear-/o1es wit QTM split ma2 /e used.
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Co!!ect o! 3et2ee! rope 'r(# < "ear-3o7 3ne o% t e %ollowing arrangements s all /e adopted %or connecting t e rope drum wit t e gear-/o1.
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5le1i/le -oint, incorporating %le1i/le geared coupling oused wit in t e drum. 5ull2 %le1i/le geared coupling /etween t e drum and gear/o1.
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#ri&e o% t e drum /2 means o% spur ring mounted on t e drum s all /e a&oided as %ar as practica/le. +hee-s Cra/:crane w eels s all /e dou/le %langed. 4 eels s all /e mounted in anti-%riction roller /earing oused in Q.M s aped /earing /rac'ets %or eas2 remo&al during maintenance. 5lange-less w eels wit guide rollers are also accepta/le. Solid w eels s all /e o% %orged rolled:cast steel. 4 eels %rom 4!! mm diameter and a/o&e ma2 consist o% ardened, rolled : %orged steel t2re o% not less t an "! mm t ic'ness, s run' on to cast iron center.
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Co(p- !" $otor s a%t s all /e connected to t e gear/o1-input s a%t t roug %le1i/le s oc' a/sor/ing coupling. @otating parts s all /e suita/l2 co&ered /2 3.15-mm t ic' s eet steel inged co&ers %or sa%et2. )n case o% single motor central dri&e %or .ong tra&el motion, output s a%t o% t e gear-/o1 s all /e connected to t e line s a%t t roug al% geared couplings. )ntermediate lengt s o% t e line s a%t ma2 /e connected t roug solid %lange couplings. 9al% geared couplings wit %loating s a%t s all /e pro&ided /etween t e w eel and t e w eel and t e line s a%t. Bear !"s < 3ear !" ho(s !"s 8nti-%riction /earings s all /e used t roug out e1cept w ere re;uired ot erwise %or tec nical reasons. B(11ers Spring loaded t2pe /u%%ers s all /e pro&ided on all t e 4 corners o% t e /ridge girders and t e end carriages %or cross and long tra&el motions respecti&el2. Motors $otors %or &arious dri&es Gra/ Crane s all /e 9ea&2 dut2 re&ersi/le crane ser&ice, totall2 enclosed, %an cooled, %oot mounted, wound rotor motor con%orming to latest edition o% )S= 325-199". Class o% insulation s all /e 5:5 >Stator:@otor? wit temperature rise limited to t at %or N<B +ullout tor;ue s all not /e less t an 275G o% %ull load tor;ue corresponding to "!G C#5. #egree o% protection %or motor s all /e )+-55. $otors %or &arious dri&es Single Girder Lnder Slung Crane: (lectric 9oist s all /e totall2 enclosed, %an cooled, %oot mounted, wound rotor s;uirrel cage induction t2pe
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con%orming to latest edition o% )S= 325-199". +ullout tor;ue s all not /e less t an 2!!G o% %ull load tor;ue corresponding to 4!G C#5. #egree o% protection %or motor s all /e )+-54. $otor selected s all /e suita/le %or %re;uent re&ersi/le, /ra'ing and acceleration. $otors s all a&e Class N<B insulation wit ma1imum temperature not e1ceeding 12!!C as measured /2 resistance met od. 8ll windings s all /e impregnated %or ser&ice in t e tropics corresponding speci%ied am/ient temperature. $otor selection s all /e done as per )S= 3177 7 1999. T e main motor s all a&e %ollowing speed ranges= a? Class $3 * $5 dut2 cranes= $ain * au1iliar2 oist .ong * cross tra&el /? Class $7 * $8 dut2 cranes= $ain * au1iliar2 oist .ong * cross tra&el "!! rpm 75! - 1!!! rpm 75! rpm 1!!! rpm
8ll motors s all a&e t e terminal /o1 at top. 5rame si6es s all con%orm to )(C Standards. 9ori6ontal %oot mounted and wit tapered s a%t e1tension. 4 ile selecting t e motor rating %ollowing s all also /e ta'en into consideration= #ut2 t2pe S4 * S5 C2clic dut2 %actor 0um/er o% switc ings per ours T2pe o% controls used )nertia o% t e motor and mec anism 8m/ient correction %actor Ser&ice %actor 4ind pressure
$a1imum permissi/le operating speed s all /e 25!G o% s2nc ronous speed or 2!!! rpm w ic e&er is less. 3&er load capacit2 15!G o% %ull load current %or 2 minutes wit out damage or permanent de%ormation. 1ii? Bra8es <ra'es s all /e #.C. electromagnetic t2pe con%irming to 8)S( Standard. T e /ra'e coils s all /e made o% copper and o% insulation class N5B.
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<ra'es s all /e designed to %ail-sa%e w ene&er t e current is interrupted eit er intentionall2 or /2 %ailure o% t e main suppl2. <ra'e circuit %orcing s all /e pro&ided %or #.C. /ra'es. #.C /ra'e circuit s all /e switc ed o%% on #.C. circuit %or ;uic' operation o% /ra'e. 8 separate set o% par'ing /ra'e %or ..T. motion s all /e pro&ided %or eac out door crane. +ower suppl2 %or t ese /ra'es s all /e o/tained %rom protecti&e panel. 1iii? L # t s2 tches @oller le&er operated, resetting limit switc es s all /e pro&ided %or all tra&el motions. 5or eac oist motion, a rotar2 cam t2pe o&er oist and o&er lower, sel%-resetting limit switc s all /e pro&ided. T is limit switc s all a&e independentl2 ad-usta/le cams %or oisting and lowering motion. T e cams s all a&e ad-usta/ilit2 suc t at end limit can /e set to wit in 1!! mm o% t e oisting or lowering motion. )n addition to t is, a /ac' up ultimate limit switc o% series: s unt gra&it2 t2pe s all /e pro&ided to pre&ent o&er oist. T e later s all /e o% manual reset t2pe. )n case o% cranes andling ot metal, t e gra&it2 limit switc s all pre%era/l2 /e o% s unt t2pe. +ro&ision s all /e made to /ridge t e gra&it2 t2pe limit switc contact /2 pus /utton: switc or an2 ot er means to lower t e load. 8n indication s all /e pro&ided to t e operator w ene&er t is limit switc as operated. Suita/le limit switc s all /e pro&ided %or slac' rope, gate:door opening, slew mec anism, gra/ closing : opening etc. w ere&er necessar2. 1i&? Res sta!ces 8ir cooled, ro/ust, ea&2 dut2, corrosion resistant punc ed stainless steel >8)S)-4!"? grid t2pe. @esistance s all /e in step wise e1ecution. )n a particular /o1 t e rating o% resistances s all /e t e same to t e e1tent possi/le. @esistance s all a&e &i/ration proo% onl2. @ated %or 1! minutes dut2. Continuous dut2 rating o% resistances s all /e pro&ided in case o% oist motions controlled /2 t 2ristor con&erters. $a1imum temperature o% resistor elements s all /e limited to 275! C at desired dut2. Suita/le tapping points s all /e pro&ided. @esistance /o1es s all /e mounted in rac's t at permit independent remo&al o% an2 selected /o1. 1&?
L "ht !", soc8et o(t-ets, 3e--s etc.

Page 63 of &29
.ig ting s all /e pro&ided in operatorBs ca/in, staircases, plat%orms and wor'ing areas. $inimum 4 nos. 4!! watts ig pressure sodium &apour %lood lig ts e;uall2 spaced >under crane girders? a/out t e crane span s all /e pro&ided along wit s oc' a/sor/ing and anti-swing suspension arrangements. $ore num/ers o% %ittings s all /e pro&ided i% re;uired %or cranes wit longer span and:or longer eig t o% li%t. 5luorescent lamps wit necessar2 %ittings s all /e used %or operatorBs ca/in, staircases, plat%orms etc. 8de;uate num/er o% and lamp soc'et outlets >2 +in, 1!8, 24E? and power soc'et outlets >3 +in, 2!8, 24!E? s all /e pro&ided along wit switc es soc'et * switc s all /e interloc'ed suita/l2. 8 and lamp >1"!4 S.S lamp wit enclosed t2pe /atter2 and wire guard? along wit su%%icient lengt >15m? o% ca/le wit a plug s all also /e pro&ided %or eac crane. 8n alarm /ell s all /e pro&ided on crane. 1&i? a5 E9( p#e!t o! pe!'a!t (! t I! case o1 pe!'a!t co!tro--e' cra!e 1o--o2 !" sha-- 3e !c-('e' o! the pe!'a!t (! t. +us /utton %or Switc %or .amps %or = = = 9oist slow, oist %ast, lower slow, lower %ast, le%t cross tra&erse, rig t cross tra&erse, %orward long tra&el, /ac'ward long tra&el, emergenc2 stop conditions. .ig ts and /ells +ower N30B indication and emergenc2 corner switc operation.
1&ii?
L(3r cat o! Grouped grease lu/rication s2stem s all /e used %or class 1, 2 and 3 dut2 cranes. .u/rication o% t e gears and pinions in t e gear/o1es s all /e splas %ed %rom t e sump. )n case o% t ree reductions, &erticall2 mounted gear/o1 > a&ing limited motion?, an oil pump s all /e %itted to ensure lu/rication o% all gears. INFORMATION TO BE FURNISHED B$ THE TENDERER FOR SINGLE GIRDER ELECTRIC UNDER-SLUNG CRANE 1. Crane 0o. 2. 0o. 3% cranes 3. T2pe o% Crane
)?.>
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4. 5. ". 7. 8.
Supplier: $a'e Capacit2 >t? Span >m? #ut2 Class Speeds >normal * Creep ? m: min a? $ain oist * creep /? 8u1. 9oist * creep c? Cross tra&el d? .ong tra&el 9. 9eig t o% li%t >m? a? $ain oo' 8/o&e %loor <elow %loor /? 8u1 oo' 8/o&e %loor <elow %loor 1!. Crane rail eig t a/o&e %loor >m? 11. $a1 w eel load >t? >wit out impact? 12. T2pe o% ca/in 13. T2pe o% oo'= a? $ain oo' /? 8u1 oo' 14. .ocation >)ndoor: 3utdoor? 15. 9oo' approac es >m? a? $ain oo' /? 8u1 oo' 1". 0o o% rope %alls, dia, construction, * /rea'ing strengt %or a? $ain oist /? 8u1 oist 17. Gantr2 rail si6e 18. Cra/ rail si6e 19. 3&er /u%%er dimension >m? 2!. 4 eel /ase 21. 4 eel diameter %or a? .T w eel /? CT w eel 22. 9andling attac ments 23. Special %eatures >weig ing de&ice etc? 24. $otor= > T2pe, '4, rpm starts: r enclosure etc? a? $ain oist /? 8u1 oist
Page 65 of &29
25. 2". 28. 29. 3!. 31.
32. 33. 34.
35. 3". 37. @.)) 8.!1
c? Cross tra&el d? .ong tra&el T2pe o% control %or eac motion wit corresponding c aracteristic cur&e= $et od o% o/taining creep speed= +ower suppl2 +ower suppl2 S...#= (lectric e;uipment speci%ication Control &oltage 8m/ient temp: (n&ironment Total weig t o% t e crane >t? <rea' up o% crane weig t >t? a? Structural /? $ec anical c? (lectrical Total weig t o% t e cra/ >t? Code o% design General arrangement drawing, incorporating t e %ront and side ele&ations, plan, oo' approac es, location o% ca/in: pendant, down s op lead, clearance dimension, andling attac ments and ot er rele&ant c aracteristics o% t e crane. .ist o% de&iation %rom t e +urc aserBs speci%ication > to /e %urnis ed in enclosed %ormat onl2? #etails o% swi&eling : rotating arrangement, i% an2, along wit sc eme. 8n2 ot er in%ormation
CI&IL +OR%S T is section o% t e speci%ication co&ers entire ci&il engineering wor' %or /uildings, tec nological structures, new e;uipment and %acilities %or all production, au1iliar2 and ancillar2 units, %oundation %or all /uildings, structures and main e;uipment descri/ed elsew ere in t is speci%ication on a T(r!8e0 3as s %or F re 1 "ht !" S0ste#. +a&ed areas, approac roads, drainage and sewerage as re;uired, trenc es, pits and all ot er miscellaneous ci&il engineering wor's, including demolition, relocation and di&ersion Ti% necessar2U o% t e e1isting %oundations, pits, trenc es, drains, underground and o&er ead ser&ices, roads, trac's, /uried ca/les, etc., %or t e proposed +ac'age s all /e in t e scope o% wor'.
8.2
T e proposed +ac'age is to /e installed in an area indicated in t e general la2out drg and situated wit in t e 0)0. +lant /oundar2. T e tenderer is ad&ised to &isit t e site
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and ac;uaint imsel% o% t e site condition and collect all suc data as ma2 /e necessar2 %or preparation o% is o%%er. T e scope s all co&er complete ci&il engineering wor' %or t e proposed F re 1 "ht !" S0ste# wit in its /atter2 limit, on t(r!8e0 3as s !c-(' !" 'es "!, s(pp-0 o1 a-- #ater a-s a!' e7ec(t o! .
8.3
Soil C aracteristics 0ormall2 moorum t2pe soil is a&aila/le upto a dept o% 3.5m .5or Sa%e <earing capacit2 o% soil ,t e Geo tec nical in&estigation report a&aila/le wit 0)0. s all /e re%erred. 9owe&er t e tenderer ma2 adopt t eir own met ods to ascertain t e sa%e /earing capacit2 o% soil at re;uired le&el. T e ma-or ci&il wor's in&ol&ed %or installation o% t e +ac'age s all pertain to t e %ollowing areas= i?)ndependent 5ire 4ater +ump ouse>@CC Construction? ii?Static 4ater Tan' wit two compartments. T e materials and ser&ices s all include /ut not /e limited to t e %ollowing i. ii. (art wor' %or %oundations, pits, trenc es, /asements, tunnels, drains, sumps, sewers, etc. @ein%orced concrete %or ra%t %oundations, spread %ootings or strip %ooting, including piles and pile caps as re;uired in %oundations. c annels, tunnels, /asements, pits, trenc es, sumps, etc. Soling and su/-grade wor' %or all %oundations, %looring, trenc es, pits and ot er underground structures 8ll doors, windows, gates, etc. @ein%orced concrete wor' in columns, /eams, %loors, sla/s, %rames and ot er superstructures @ein%orced concrete wor' in supporting structures o% e;uipments 8ll masonr2 wor' in superstructure and partition 8ll %inis ing wor' in %looring, wall-cladding and ceiling 8ll necessar2 waterproo%ing, eat resisting, %ireproo%ing and anti-corrosi&e treatment to /uilding structures and %oundations
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8.!4
8.!5
iii. i&. &. &i. &ii. &iii. i1.

8ll plum/ing, rainwater drainage, sanitar2 sewerage wor's %or all /uildings, roadwa2, par'ing, pa&ed areas and open spaces wit in t e /atter2 limits o% t is speci%ication 1i. 8ll temporar2 /uildings, o%%ices, roads, trac's and ser&ices %or construction o% t e 5ire %ig ting +ac'age. 1ii. @emo&al o% all materials, cleaning, and anding o&er o% site in a wor'a/le manner. )t s all include all wor's re;uired %or completeness o% t e pro-ect. 8ll t e materials and wor'mans ip s all con%orm to rele&ant <ureau o% )ndian Standard norms and speci%ications. @.)6 Des "! para#eters i. .oading, design o% structures, permissi/le stresses and ot er design criteria s all generall2 /e in accordance wit t e latest edition o% rele&ant ).S. Codes and practices, &i6., )S 7 45"V )S 7 875V )S 7 1893V )S 7 2974V )S 7337!V )S 7 178"V )S 7 432V etc. 5or guidelines on #esign /asis and $aterial * wor'mans ip respecti&e clauses:c apters o% Spec 1 cat o!s 1or C / - E!" !eer !" +or8s 4::-C / -GS-)?5ma2 /e re%erred. ii. 8ll /uildings and supporting structures including connections and %oundations s all /e designed to wit stand t e most ad&erse com/ination o% loads @igidit2 o% t e /uilding structures in /ot directions and sta/ilit2 o% structures %or worst com/ination o% loadings s all /e ensured. 3t er precautions li'e waterproo%ing, dust proo%ing, protection %rom eat, sound and corrosion etc. s all also /e considered. Concrete and rein%orced concrete structures i. Concrete and rein%orced concrete structures including superstructures and underground construction s all /e designed and constructed in accordance wit ).S. Codes. 9owe&er, concrete o% %ollowing minimum grades s all /e used= $udmat @.C.C.
1.
iii.
8.!7
$5 $25
Page 68 of &29
5or %looring : pa&ing etc. ii. iii.
$ 2! grade concrete ma2 /e used.
T e mi1-design s all /e adopted %or proper strengt , wor'a/ilit2 and ser&ice re;uirement. 8dditi&es and retarding agents %or concreting. %loor ardening additi&es, acid resisting and integral waterproo%ing compounds s all /e added to t e concrete depending upon re;uirements.
8.!8
5inis es i. 8ll %loor %inis es s all /e as per <.).S.: speci%ication and s all meet t e %unctional re;uirements. ii. T e wall %inis es s all /e as per <.).S.: speci%ication. iii. T e roo% %inis es s all /e as per <.).S.: speci%ication. 0ecessar2 %alse ceiling s all a&e to /e pro&ided as per tec nological re;uirements and speci%ied elsew ere in t is speci%ication. 8ll concrete roo%s e1posed to weat er s all /e pro&ided wit water proo%ing treatment. #rainage o% rainwater %rom roo% s all /e ensured /2 rainwater down comers and proper slope. 8ll doors and windows s all /e pro&ided as per tec nological re;uirements. 8de;uate natural lig ting and &entilation s all /e planned and pro&ided %or general /uildings. T e connections o% t e roads, drains and sewer lines, /eing pro&ided %or t e pro-ect s all /e properl2 co-ordinated wit t e e1isting lines. ii. iii. T e roadwa2s s all /e so laid as to %acilitate mo&ement o% materials, e;uipment, products, etc. as well as operators and e1ecuti&es. 0ecessar2 pa&ed areas s all /e pro&ided around plant and au1iliar2 units %or car- par'ing. #rainage and sewerage
Page 69 of &29
8.!9
8.1!
8.11 8.12
8.13
8.14
i. ii.
iii.
i&.
8ll rain water drainage, sanitar2, %aecal sewerage and plum/ing s2stem %or all /uildings and open areas s all /e pro&ided, as re;uired. 8ll ser&ice pipelines, water suppl2, plum/ing and ot er utilit2 pipelines and electrical wiring wit in t e ancillar2 and au1iliar2 /uildings o% @C: $asonr2 construction, will /e concealed wit in t e masonr2, concrete wor' etc. 8ll au1iliar2 and ancillar2 /uildings ousing toilets: drin'ing water %acilities s all /e pro&ided wit water storage tan's at roo% o% t e /uilding separatel2 %or drin'ing and sanitar2 purposes. 8ll sur%ace drains s all /e co&ered wit pre cast sla/s: gratings, as per re;uirements w ere e&er necessar2.
8.15
T e tenderer s all di&ert, at is own cost, an2 un%oreseen underground %acilities, pipelines t at need to /e di&erted during ci&il construction in consultation wit t e client. T e tenderer s all indicate t e ;uantities o% ma-or ci&il engineering wor's li'e e1ca&ation ,+CC, @CC, rein%orcing steel, inserts, s uttering, /ric'wor', roadwor', pipelines, etc. under is scope o% wor' as indicated under ANNECURE -I. T e Contractor s all not ma'e an2 additional claim i% t e total concrete ;uantit2 or ;uantit2 o% an2 o% t e ci&il engineering items re;uired %or completion o% t e entire pac'age as per terms o% contract e1ceed t e ;uantit2 indicated /2 t e Contractor in 8nne1ure-) o% t is section T e tenderer s all also indicate soil in&estigation and site: topograp ical sur&e2, i% an2, to /e underta'en /2 im. T e tenderer s all indicate t e estimated num/er o% ci&il engineering drawings. Tin e;ui&alent 81 si6eU T e success%ul tenderer s all su/mit all /asic engineering, sc ematic and su/se;uentl2 detailed ci&il engineering drawings along wit rele&ant load data and design calculations %or clientBs appro&al as indicated under ANNECURE -II as per sc edule: documentation re;uirements. Ge!era- !str(ct o!s
Page 70 of &29
8.1"
8.17
8.18
8.19
1?
.ocal conditions T e tenderer, /e%ore su/mitting is tender, s all &isit t e site and ascertain t e local conditions, la/our rules, a&aila/ilit2 o% construction materials, tra%%ic restrictions, all o/structions in t e area and also ascertain all site conditions including t e su/-soil conditions and s all allow %or an2 e1tras li'el2 to /e incurred due to all suc conditions in is ;uoted prices. 8%ter t e award o% wor' no additional claims will /e entertained on t ese accounts under an2 circumstances, w atsoe&er, %rom t e tenderer.
2?
Setting out and le&eling T e tenderer s all set out and le&el t e wor' and will /e responsi/le %or t e accurac2 o% t e same. 9e is to pro&ide all instruments and proper ;uali%ied sta%% wit la/our %or getting is wor' c ec'ed /2 (ngineer, i% so desired /2 t e (ngineer. Suc c ec'ing, i% an2, s all not, owe&er, relie&e t e Tenderer in an2 wa2, o% is responsi/ilit2 %or correct setting out.
3?
Sa%et2 T e tenderer s all ta'e ade;uate precautions to ensure complete sa%et2 and pre&entions o% accidents at site and s all /e responsi/le %or t e same. T e sa%et2 precautions s all con%orm to t e sa%et2 regulations prescri/ed /2 t e Sa%et2 Code %or constructions and rele&ant )ndian Standard Codes, some o% w ic are stated /elow= )S 37"4=1992 = Sa%et2 Code %or e1ca&ation wor' )S 4!14=19"7 )S 4!81=198" )S 4138=1977 )S 7923=1985 = = = = Sa%et2 @egulations %or sca%%olding wor' Sa%et2 Code %or drilling and /lasting operations Sa%et2 Code %or wor'ing wit compressed air Sa%et2 Code %or wor'ing wit Constructions mac iner2
4?
Heeping wor' %ree %rom water T e tenderer s all pro&ide and maintain at is own cost, pumps and ot er e;uipments to 'eep t e wor's %ree %rom water and continued to do so until t e anding o&er o% t e wor's
Page 71 of &29
@u//is T e tenderer s all 'eep t e site clear on a continuous /asis o% all ru//is etc. w ic ma2 arise out o% t e wor' e1ecuted /2 im and dispose t em suita/l2 in allotted areas. <enc $ar's, @e%erence +illars etc. T e tenderer s all protect all /enc mar', and re%erence pillars :lines including ground water gauges %rom damage or mo&ement during wor'ing. )n case o% an2 damage t e tenderer s all a&e to restore t e same to its original condition at is own cost. "? Standards Lnless ot erwise mentioned in t e speci%ications, all applica/le codes :standards as pu/lis ed /2 t e <ureau o% )ndian Standards on t e date o% award o% contract s all go&erned t e wor' in respect o% design, wor'mans ip, ;ualit2 and properties o% materials, met od o% testing and ot er pertinent %eatures. )n case o% &ariance /etween t is speci%ications and )S Codes: Standards, t e pro&isions o% t is speci%ication s all pre&ail upto t e e1tent o% suc &ariance. 7? #rawings 4or' s all /e carried out as per drawings prepared /2 t e tenderer and appro&ed /2 t e Client. T e drawings s all include General 8rrangement, s uttering, e1ca&ation, anc orage plans, /olt plans, insert plan and details, conduit plans, etc re;uired %or e1ecution o% t e -o/. 8lso, t e design calculations s all /e su/mitted in re;uisite num/er o% copies >as mentioned elsew ere? %or t e appro&al /2 t e Client. 8? T is speci%ication s all /e read in con-unction wit t e general conditions o% contract and ot er pro-ect re;uirement pro&ided in t e ot er &olumes containing special conditions o% contract, instruction to /idders, special instructions to /idders etc.
5?
Page 72 of &29
Speci%ication %or ci&il wor's comprises, /esides t is section, one &olume o% Spec 1 cat o!s 1or C / - E!" !eer !" +or8s 4::-C / --GS-)?5 T is &olume s all also %orm part o% t is section and t ere%ore s all /e read in con-unction wit t is section.
ANNECURE-I Est #ate' D(a!t t es 1or C / - +or8s 1? (1ca&ation 2? +iling 3? @CC 4? +CC 5? S uttering "? @ein%orcement Steel 7? +CC 5looring 8? 5inis ing 9? )nserts: <olts 1!?8n2 miscellaneous items deemed necessar2 %or success%ul completion o% ci&il wor's o% t e proposed plant.
Page 73 of &29
ANNECURE -II L st o1 C / - E!" !eer !" Dra2 !"s a!' Doc(#e!ts 1or Appro/a-GI!1or#at o! Group 7 1 = )tem 0o. 1. 2. 3. 4. 5. ". 7. 5or 8ppro&al #escription #rawing num/ering s2stem .ist o% drawings, wit drawing 0os. and title <asic design criteria and loading %or all /uildings, structures and %oundations. Site plan:la2out drawing wit /atter2 limit in 1=5!! scale #esign calculations along wit load data %or /uildings, %oundation %or e;uipment and structures, au1iliar2 etc, >design calculations s all /e su/mitted along wit or /e%ore su/mission o% G.8. and design drawings?. General arrangement plan and sectional drawings wit all dimensions and details %or %oundation o% e;uipment and structures , au1iliar2 %acilities etc. .a2out and sectional details o% drainage, sewerage networ' wit all in&ert le&els slopes, si6es, dimensions, man oles top le&el etc.
Group 7 2 = 5or in%ormation and comments, i% an2 )tem 0o. 1. 2.. )A.) !9.1 #escription #etail rein%orcement drawings. #etail o% /olts, inserts: em/edment , co&erings,etc. STEEL STRUCTURAL +OR%S G(0(@8. Steel structural wor' in +ump ouse will co&er all items related to c e;uered plate co&ers %or ca/le and ot er trenc es, &al&e operating plat%orm wit andrails made o% mild steel tu/es, stairs, ladders, etc. and monorails %or electric crane. T e plat%orms s all /e made o% c e;uered plate, and ot er structures li'e posts, supporting /eams, stairs, ladders, monorail /eams, etc. o% structural steel construction. $onorails to /e erected at t e so%%it o% @CC /eam o% a/o&e mentioned +lant /uildings.
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!9.2
Scope o% wor' 1. +reparation o% general arrangement o% all structural wor' %or t is -o/ satis%2ing tec nological re;uirements. 2. Structural anal2sis, design and preparation o% design drawings %or all t e related steel structures, preparation o% %a/rication drawings as appropriate %or %a/rication and erection o% steel structures. 3. Suppl2, %a/rication and erection o% t e steel structures satis%2ing all tec nological re;uirements. 4. Suppl2, %a/rication and erection o% structures s all include suppl2 o% all accessor2 tools, tac'les, la/our, consuma/les, %asteners, paints and painting wor' to t e satis%action o% t e purc aser
!9.3
#(S)G0 +8@8$(T(@S Structures made o% structural steel s alll /e designed as per )S=8!! 7 2!!7. .oading will /e ta'en as per )S=875 7 1987 >+art 1,2,3 and 5? in addition to t e tec nological loads indicated /2 t e e;uipment manu%acturer : supplier. Seismic loads s all /e ta'en %rom )S=1893 7 2!!2.
!9.4
$8T(@)8. 35 C30ST@LCT)30 T e material %or t e structures to /e designed s all /e as %ollows =a? /? c? 8ll steel rolled sections and plates will con%orm to )S=2!"2 >Grade 8? 7 C e;uered plate s all con%orm to )S=35!2 7 1994. Steel tu/es %or andrail s all con%orm to )S=11"1- 1998. $(T93# 35 C30ST@LCT)30 Steel structures to /e %a/ricated will generall2 /e o% welded construction. Co&ered electrodes will con%orm to )S=814 7 1991. (lements will /e %a/ricated in largest possi/le dimensions optimal wit t e transport re;uirement so as to minimise site wor'. Site connection will /e eit er /2 permanent /olts or /2 erection /olts %ollowed /2 site welding. (rection /olts s all /e retained in position a%ter site 7 welding.
!9.5
!9."
58<@)C8T)30 5a/rication o% structures will con%orm to )S=8!! 7 2!!7 and ot er related standards. 8ppropriate se;uence and procedure o% welding will /e %ollowed during %a/rication
Page 75 of &29
!9.7
o% structures so t at distortions: de&iations in t e %a/ricated structures are 'ept to a minimum. )0S+(CT)30 8ll structures s all /e o%%ered %or inspection /2 t e purc aser. $aterial certi%icate %or t e %a/ricated structures will also /e pro&ided.
!9.8
(@(CT)30 (rection s all /e carried out as per applica/le standards, drawings, speci%ications and regulations. T e erection tolerance s all /e wit in t e standard speci%ied limits.
!9.9
+8)0T)0G 8%ter sur%ace preparation as per Swedis standard S8 2 1:2 all structures s all recei&e one coat o% red o1ide 6inc c romate primer at s op a%ter %a/rication and anot er coat o% t e same primer at site a%ter erection, %ollowed /2 two coats o% %inis ing paints o% appro&ed ;ualit2 and ma'e.
1!.!!
ELECTRICAL S$STEM T e intent o% t is speci%ication is to ena/le tenderer to su/mit a detailed o%%er %or $CC, .T motors, .CS, power and control ca/les, 4elding soc'et outlets and eart ing materials etc. %or %ire %ig ting pump ouse %or $:s 0eelanc al )spat 0igam .td at #u/ri, 3rissa on turn 'e2 /asis. T is speci%ication s ould /e read toget er wit General Tec nical Speci%ication GTS >0o.GS-!3? %or (lectrics, )nstrumentation and Telecommunication %or detailed speci%ication o% e;uipment :components. .ist o% +re%erred ma'es, General conditions o% contract >GCC? * ot er commercial term * conditions are Separatel2 attac ed wit t is speci%ication. T ese are complementar2 and an2t ing laid down in one and not in ot er will /e deemed as /inding, as t oug laid down in t e Tender speci%ication as a w ole. )n case o% con%lict /etween t e Tec nical speci%ication and GTS, t e Tec nical speci%ication >TS? s all pre&ail.
1!.1
SCOPE OF +OR% T e scope o% wor' s all include t e %ollowing. 1.! #esign, engineering, manu%acture : procurement, assem/l2, painting, s op testing, inspection, suppl2, pac'ing, %orwarding, transportation, loading * un loading , storage at site including andling along wit watc and ward ser&ice, transportation %rom store to site >e;uipment %oundation? o% all electrical e;uipments including erection accessories, ca/les, pipes and all associated ardware as re;uired %or completeness o%
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electrical s2stem in all respect along wit erection, testing and commissioning o% t e complete s2stem supplied /2 tenderer. $CC >catering t e loads o% %ire water electrical dri&en pumps, -oc'e2 pumps, motor operated &al&es, electric oists etc.?, .T motors, .ocal control stations, motori6ed &al&es etc. re;uired. .T +EC +ower * Control ca/les, 1.1 'E grade. 3 0os. o% power suppl2 %eeders > "38 - 1 0o, 1258 - 2 0os? s all /e pro&ided in t e TendererBs $CC %or purc asers use. +ower suppl2 %eeders %or Eentilation s2stem >i.e. 5nos. o% e1 aust %an eac a&ing !.2'w motor rating ? %or %ire water pump ouse * electrical premises s all /e pro&ided in t e t e tendererMs $CC. (art ing o% motors, panels, local control stations * -unction /o1es etc. s all /e under tendererMs scope. .ig tning protection s2stem i% re;uired s all /e pro&ided /2 tenderer. $inor ci&il wor's li'e c ipping, digging * grouting %or installation o% supports, stands, panels and c ipping and re%illing o% t e %loors %or conduits. +lugging o% unused : /alance openings in walls, conduits etc. Suppl2, la2ing, termination at /ot ends o% all power, control and special ca/les along wit all sundr2 erection materials re;uired %or installation and connecting up o% electrical e;uipment s all /e in t e tendererMs scope. Ca/les will generall2 /e laid t roug e1isting ca/le route >tunnel : trenc : structure? in t e s op .0ew ca/le routes, erection * erection material as re;uired s all /e considered. (1ca&ation, /ac' %illing and le&eling o% under ground /uried trenc es wit in t e /atter2 limits s all /e in t e tendererBs scope. Ci&il assignment drawing related to electrical wor' wit in t e /atter2 limit o% suppl2 and ser&ices o% t e tenderer s owing proposed location o% electrical panels, indicating re;uirement o% ca/le trenc es, conduits, inserts, cutouts etc. +reparation o% $otors * components list, single line diagram, power and control sc ematic %or all t e %ire %ig ting pump ouse 'eeping in &iew t e tec nological re;uirement s all /e in t e tendererMs scope. +reparation o% t e ca/le sc edule and e1ternal connection diagram o% all t e ca/les s all /e in t e tendererMs scope.
3.! 4.! 5.!
".! 7.!
8.!
9.!
1!.!
11.!
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Signals e1c ange wit +.C >i% an2? s all /e wired up to t e purc aser +.C to /e located in t e $ain 4ater s2stem pump ouse. Spare contacts o% main * au1iliar2 units o% $CC to /e %ull2 wired up to $CC terminal /loc's. Statutor2 appro&al %rom Go&ernment agencies. 5ees * all ot er pa2ments s all /e /orn /2 t e Tenderer. Sa%et2 clearance %rom t e purc aser >0)0.?. +8T * 58T a%ter su/mission o% all 8s-/uilt drawings. 8ll t e e;uipments : panels s all /e %rom t e latest product ranges o% reputed manu%acturerMs as per t e list o% +re%erred ma'es o% 0)0.. +urc aser : Consultant reser&es t e rig t o% selecting particular ma'e and model o% e;uipments : s2stems wit a &iew o% standardi6ation o% t e w ole plant. T e tenderer s all compl2 wit suc re;uirements. Suppl2 o% commissioning spares. Suppl2 o% 2 2ears maintenance spares along wit item wise prices. Suppl2 o% 8s /uilt drawings and documents. 8ll tools, tac'les, instruments, man power >s'illed * uns'illed? re;uired %or testing and commissioning o% t eir e;uipment s all /e arranged /2 t e tenderer. 8n2 special tools, tac'les and instruments t at ma2 /e re;uired %or erection, testing and commissioning s all /e included in t e scope o% suppl2. 8n2 e;uipment : accessories not e1plicitl2 indicated in t is speci%ication, /ut considered essential %or proper %unctioning o% tec nological e;uipment and process s all /e included in t e TendererMs scope o% wor' * suppl2. BATTER$ LIMIT A5 FIRE FIGHTINIG PUMP HOUSE LOADS. Scope o% tenderer starts %rom out going terminal >415E 8C, T+0, 5! 96? o% t e purc aserMs su/station .TSS 5 located appro1. 25!m %rom %ire %ig ting pump ouse. +urc aser s all pro&ide t e %ollowing. Two nos o% 415 E, T+0, 5! 96 %eeders o% re;uired rating at purc aser power source %or power suppl2 to incomer o% t e tendererBs $CC to /e located in t e %ire %ig ting pump ouse electrical premises. 9owe&er all t e incoming .T ca/les including suppl2, la2ing and terminationalong wit erection and termination accessories s all /e in t e scope o% t e tenderer. Tenderer s all consider a ca/le lengt o% appro1. 25!m %or estimation purpose. Tenderer s all indicate unit rate %or ca/le %or an2 addition:deletion during detail engineering stage. 0um/er o% ca/le runs and ca/le si6e s all /e decided /2 t e tenderer as per design calculation. @e;uired num/ers o% %eeders
13.! 14.! 15.!
1".! 17.! 18.! 19.! 2!.! 21.!
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along wit rating s all /e indicated /2 t e tenderer in t eir o%%er.
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EARTHING S$STEM 8ll t e new e;uipments >motors, panels, -unction /o1es, distri/ution /oards etc.? S all /e suita/l2 eart ed as per latest )S and suita/l2 interconnected wit near/2 >appro1. 3!m? plant main eart ing ring.
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STANDARDS T e #esign, manu%acture, per%ormance, >including sa%et2, eart ing and ot er essential pro&isions? o% e;uipment and accessories co&ered under t is speci%ication s all in general, compl2 wit t e latest issue o% .atest applica/le Standards and Codes o% +ractices pu/lis ed /2 )ndian )nstitution ><)S?. )+SS >)nterplant Standards %or Steel )ndustr2?. )ndian (lectricit2 @ules * statutor2 re;uirements o% Central Go&t. and State Go&t. (;uipment compl2ing wit ot er recogni6ed Standards suc as )(C, <S, E#(, #)0, )((( will also /e considered, i% it ensures per%ormance e;ui&alent to or superior to )ndian Standards. T e components and materials used and t e e;uipment supplied s all con%orm to ig standards o% design, engineering and wor'mans ip and s all /e suita/le %or e%%icient operation and relia/le ser&ice in steel plant conditions. 8ll %ield mounted e;uipment li'e motors, limit switc es, -unction /o1es, solenoids etc. s all a&e dust * water protected enclosure minimum - )+-55.
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STATUTOR$ REDUIREMENTS T e latest &ersion o% t e %ollowing statutor2 regulations s all /e %ollowed %or design o% electrical s2stem= ) W ndian (lectricit2 8ct, 191!. ) W ndian 5actor2 8ct, 1948. ) W ndian (lectricit2 @ules, 195". ( W lectricit2 regulator2 commission 8ct, 1998 >as amended in 2!!2?
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LANGUAGE < UNITS 8ll nameplates and inscriptions o% e;uipment, operating and maintenance manuals, tec nical catalogues, test certi%icates, e1planator2 notes in drawings etc. will /e in (nglis language. 8ll danger and caution notice /oards will /e in 9indi * (nglis .
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#imensions and weig ts o% all e;uipment and cali/rations o% all instruments:apparatus will /e in $etric units.
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GENERAL INSTRUCTIONS TO TENDERER T e tenderer as to strictl2 agree to all t e terms and conditions mentioned in t e tender documents and an2 de&iation %rom t em s all /e categoricall2 stated in writing * accepted /2 +urc aser in writing prior to placement o% order. T e tenderer s all su/mit a /ar c art indicating starting and completion time o% eac acti&it2 suc as preparation o% drawings, manu%acture, inspection at wor's, pac'aging and %orwarding. T e tenderer s all stud2 t e speci%ication and satis%2 imsel% regarding t e wor'a/ilit2 o% t e proposed s2stem and s all ta'e %ull responsi/ilit2 %or t e design o% t e e;uipment w ere&er applica/le, ;ualit2 o% t e material, wor'mans ip, guaranteed operation and smoot per%ormance, etc o% t e e;uipment. 8ll panels in a room s all /e pre%era/l2 o% same eig t and colour so as to %orm a panel line up w ic will a&e good aest etic appearance.
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MA%E OF EDUIPMENT $a'es o% all e;uipment, instruments etc. accessories, s all /e selected out o% +urc aserBs C+re%erred ma'es o% e;uipment and suppliesD >$(C:A"93.11.37.#3C-!2,@-!,$a2 2!!"?. 3nl2 one ma'e s all /e adopted %or eac t2pe o% e;uipment considering plant standardi6ation. T e +urc aser as t e option o% selecting t e ma'e in t e interest o% standardi6ation and t e tenderer s all a&e to suppl2 e;uipment o% t e particular ma'e, i% so re;uired. )tems %or w ic ma'e is not speci%ied, prior appro&al as to /e o/tained %rom t e purc aser:its consultant %or selecting t e ma'e. 8dditionall2, %or 030 #@843LT $CC %ollowing ma'es s all /e %ollowed = $CC>030 #@843LT?= 8.ST3$: G(+C : T(C903C3$$(@C( C30S4T: S)($(0S: CG.: +(C30 .*T:
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AMBIENT CONDITIONS OF SHOP UNITS Generall2 %ollowing am/ient temperature s all /e considered unless speci%icall2 agreed. S-. No S op 1. a? Con&erter /a2 /? 3t er areas in t e s op. 2. 3. 4. (lectrical +remises Ca/le /asements : tunnels Control rooms-8ir conditioned I"! #eg.C I55 #eg.C I 5! #eg. C I 5! #eg. C I 24 #eg. C
Area
Data
(;uipment selection and derating s all generall2 /e /ased on am/ient temperature o% I 5! #eg.C. T e e;uipment o%%ered s ould /e suita/le %or smoot , e%%icient and trou/le %ree ser&ice in t e tropical umid climate pre&ailing at plant site and under t e a/o&e am/ient temperature conditions. )n ot areas o% ig er temperature conditions, t e e;uipment s all /e ade;uatel2 protected against damage %rom radiant eat and ot air. T e e;uipment s all /e designed to gi&e e%%icient and relia/le per%ormance under ea&2 steel mill conditions and s all /e suc t at t e ris's o% accidental s ort-circuit due to animals, rodents and &ermin are o/&iated. :).:) PO+ER SUPPL$ DETAILS < STANDARD &OLTAGE LE&ELS .T8C Control Eoltage
415E, 3 + ase, 5!96, 4wire, solidl2 eart ed s2stem. 24! E 8C I:- 1!G o/tained using
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suita/le control trans%ormer. Solenoid &al&es )llumination s2stem Eoltage solenoids %or 415E, 1!!8, 3 pin plus eart wit plug interloc'ed switc . 24 E #C, uneart ed. 24!E 8C, 5! 96.
Soc'ets %or welding purposes Eoltage solenoids %or
$onitoring and signaling in electronic installations, mimic panels
24E, #C
T e t ree p ase s2mmetrical s ort-circuit ratings s all /e as gi&en /elow=S-.No . 1. 2. &o-ta"e "." 'E 415E switc gear Data 4! '8 %or 3 sec. 5!'8 %or 1 second
-Per# ss 3-e &ar at o!s. As spec 1 e' ! GS 4Ge!era- Spec 1 cat o!5-), - Ut - sat o! Le/e-s LT S$STEM Eoltage %or motors o% rating 2!!'4 * less t an 2!!'4. +ermissi/le &oltage dip on starting o% t e largest .T motor :).:: DESIGN DRA+INGS AND DOCUMENTS TendererBs scope o% wor' %or all design drawings and documents s all /e as gi&en /elow=
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415E , 3 p ase , 44ire, 5!96. 15 G o% t e nominal &oltage at t e motor terminal.
Tenderer s all also %urnis so%t copies o% all t e drawings indicated /elow and drawings o% tec nological la2out:units. 8ll design, engineering and manu%acturing drawings s all /e re;uired to /e appro&ed /2 +urc aser:Consultant. 4or' s all /e carried out e1actl2 as indicated on t e appro&ed drawings and speci%ication. 0o alterations s all /e made wit out prior written appro&al /2 purc aser : is consultant. T e tenderer s all c ec' all t e drawings prepared /2 t em and:or recei&ed %rom t eir &endors:supplier:su/-supplier and satis%2 t emsel&es a/out t e correctness o% drawings /e%ore issuing to +urc aser:Consultant. 8%ter c ec'ing, properl2 stamped drawings s all /e sent to +urc aser:Consultant %or appro&al : clearance. Comments on all drawings will /e %orwarded to tenderer %or incorporation and resu/mission. T e appro&al o% drawings w ere&er applica/le /2 purc aser or t eir aut ori6ed representati&e does not a/sol&e or relie&e t e tenderer %rom an2 o% is o/ligations under t is contract and e s all /e w oll2 and solel2 responsi/le %or t e satis%actor2 operation and guaranteed per%ormance o% is suppl2. 1!.11.1 #rawings and documents to /e %urnis ed along wit t e Tender= Tenderer s all go t roug t is tec nical speci%ication t oroug l2 to understand t e pro-ect:purc aserBs re;uirements. T e2 s ould speci%icall2 list out t e e1clusions:de&iations. 1. .ist o% electrical panels * mounted electrics and all ot er electrical items re;uired to complete t e s2stem etc. 2. $otor * component list, including H4 rating, Eoltage rating, @+$ dut2, degree o% protection, t2pe o% construction * e;uipment description, motor tag no. etc. 3. Single line diagrams o% $CC etc. * t2pical control sc eme o% a #3. :@#3. %eeder indicating inputs * outputs considered. 4. Connected load >C.? : ma1imum demand >$#? o% $CC.
5. +roposed location o% electrical premises, ca/le tunnels:3&er ead Ca/le, Structures etc. including tentati&e (;uipment la2out in electrical premises . ". Ln-priced cop2 o% list o% e;uipment. 7. <asic details o% all tec nological control s2stems. 8. .ist o% de&iations, i% an2, %rom Tec nical Speci%ication * G.T.S.
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9. .ist o% spares %or 2 2ears normal operation * commissioning spares. 1!. .ist o% insurance spares. 1!.11.2 #rawings:documents to /e %urnis ed %or 8ppro&al o% t e Client:Consultant /2 t e Success%ul Tenderer= 1!.11.3 .ist o% electrical panels * mounted electrics o%%ered li'e $CC and all ot er electrical items re;uired to complete t e s2stem etc. G8 drawings, single line diagrams, control sc emes, wiring diagrams o% panel. +anel General 8rrangement drawing wit internal and e1ternal la2out o% component, sectional &iew etc. (lectrical * Control room la2out drawing s owing disposition o% panels wit dimensional details. Tec nical data s eets %or ..T $otors, Ca/les, solenoids, limit switc es and ot er %ield de&ices. Ca/le la2out drawings in ca/le tunnel, ca/le c annels, o&er ead ca/le structure >as applica/le?, and incoming ca/le route etc. S2stem grounding : eart ing sc eme wit la2out * calculation.. +ower * control ca/le sc edule. Calculation %or si6ing o% power ca/les %or all incomer and out going %eeders including &oltage drop calculation. A8+ %or (lectrics. (;uipment la2out, ca/le la2out, ca/le tra2 la2out, eart ing la2out, lig tning protection s2stem la2out. Tenderer s all pro&ide suita/le pro&ision: structural supports %or installation o% Ca/le tra2s and t e maintenance plat%orm %or ca/le tra2s. #rawings : documents to /e %urnis ed %or @e%erence= $otor * component list. +er%ormance cur&es %or $otors. Termination drawing. .ist o% inter%aces : data e1c ange wit purc aserBs e;uipment. .ist o% alarms , annunciations, logic diagram and interloc' sc eme 5unctional description .a2out o% electrical e;uipments:motors etc . Tec nical particulars, catalogues, literature etc . Spare part list and drawings )nstruction %or storage :erection, testing * commissioning. 3peration and maintenance manuals. 5inal test certi%icates
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8s /uilt drawings Terminal plan drawings, e1ternal connection diagrams %or all panels. Ci&il drawings s owing opening and inserts re;uirements , Static and d2namic loading o% all ma-or e;uipment. .a2out o% ca/le tra2s in ca/le cellars inside t e su/station * ot er electrical premises, ca/le c annels, ca/le tunnel, o&er ead ca/le structures, ca/le s a%ts etc. 3ne set o% reproduci/le o% M8s /uilt drawingsM %or all e;uipment s all /e su/mitted immediatel2 a%ter commissioning o% e;uipment. 9eat losses * load data, Eentilation re;uirements 5inal test * cali/ration certi%icates and guarantee certi%icate: warrantee certi%icate. 4iring diagram * operation manual. SPARES I5 Spare 1ee'er < 1ee'ers ! MCC .
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8t least 3!G o% %eeder control modules co&ering t e range o% motors used su/-ect to minimum o% two modules in eac /us section s all /e pro&ided as spare. T ese spare cu/icles: modules s all /e complete wit t e circuit /rea'ers : contactor : starters : ot er accessories and s all /e %ull2 wired. 1258 -20os, "3 8 -1 0os. s all /e pro&ided %eeders %or purc aser use. T e tenderer s all also include suppl2 o% all commissioning spares along wit e;uipment, w ic s all /e re;uired during testing and commissioning wit out an2 e1tra cost. SPECIFICATION OF EDUIPMENTS < COMPONENTS . As per GS-),
INSTRUMENTATION Ge!era1. $easurement and control e;uipment o%%ered s all /e complete in all respect in line wit t is speci%ication. 8n2 e;uipment : accessories not e1plicitl2 indicated in t is speci%ication, /ut considered essential %or proper %unctioning o% e;uipment and process s all /e included in TendererBs scope o% wor' and suppl2. Client : Consultant reser&e t e rig t o% selecting particular ma'e and model o% instrumentation e;uipment wit a &iew to standardi6ation o% t e w ole plant. T e Tenderer s all compl2 wit suc re;uirements. 8ll t e instruments s all /e %rom t e latest product ranges o% reputed indigenous manu%acturers as %ar as possi/le.
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ii? :).:, ::.) ::.:
2.
3.
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Scope o1 +or8 < S(pp-0 TendererBs scope o% wor' and suppl2 s all include design, engineering, manu%acture:procurement, assem/l2, cali/ration, s op testing, inspection, painting, pac'ing, transportation to site including loading, unloading, storage * andling o% all instrumentation * automation items including electrical accessories, ca/les, pipes, erection accessories, panels: ca/inets and all associated ardware, as re;uired %or completeness o% instrumentation * automation s2stem in all respect along wit site %a/rication, erection, remo&al * re-installation i% necessar2, testing >including site cali/ration, impulse pipe lea' test * loop c ec'ing? and commissioning o% t e complete s2stem. TendererBs scope o% wor' pertaining to suppl2 s all /roadl2 include, /ut not limited to, t e %ollowing= 1. 2. 3. Suppl2 o% all t e instrumentation and control e;uipment, etc. Suppl2 o% signal, control, power suppl2 ca/les, and ot er special ca/les as re;uired %or completeness o% -o/. Suppl2 o% all t e re;uired conduits, per%orated ca/le tra2s, tra2 co&ers, ca/le ducts, -unction /o1es, pull /o1es, impulse pipes * tu/es, %ittings, isolation &al&es, e1pander : reducers %or pipeline mounted instruments, ot er erection materials, accessories * consuma/les as re;uired %or completeness o% erection o% all t e supplied instrumentation * control e;uipment including ca/le la2ing on a total turn'e2 /asis. Suppl2 o% suita/le enclosures: canopies %or t e transmitters: electronic %ield de&ices. Suppl2 o% eart ing materials including ca/les %or power and instrument signal eart ing. Suppl2 o% all t2pes o% consuma/les li'e industrial gases >o12gen, acet2lene * .+G, etc.?, welding electrodes, %iller wires, grinding w eels, sol&ent %or cleaning tools, te%lon tapes, insulation tapes, lugs, %errules, slee&es, gas'ets, nuts * /olts, em/ossing gun tape, ca/le:wire tie, wire rein%orced +EC %le1i/le conduits, materials %or grouting, metallic tag plates, %illing * ma'ing o% small ci&il pedestals: %oundations, paints etc., as re;uired %or e1ecution o% t e complete -o/. Suppl2 o% steel structure e.g. angles, c annels, pipes, plates etc. %or instrument stands, ca/le structures:supports etc. Suppl2 o% an2 ot er erection ardware: material not speci%icall2 mentioned, /ut re;uired %or correctness * completeness o% t e -o/ s all also /e included in t e scope o% Tenderer. Su/mission o% all t e drawings * documentation, as per re;uirements indicated at clause no. 1.!5 o% t e tec nical speci%ication. 5unctional write-up o% t e 2drant s2stem also s all /e pro&ided /2 t e Tenderer.
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4. 5. ".
7. 8. 9.
1!.
5ollowing )nstrumentation e;uipment s all /e included in t e list o% Two 2ears operation * maintenance spares /2 t e Tenderer= +ressure Gauge= 4 nos. +ressure switc = 4 nos. Capacitance t2pe le&el switc =2 nos. Glass %uses= 2!G Tenderer is %ree to include an2 ot er instrumentation e;uipment in t e a/o&e list. 8rrangement o% and participation in inspection o% instrumentation * control e;uipment /2 Client and: or is representati&e. +reparation and su/mission o% all as-/uilt drawings and documentation. include,
11. 12.
TendererBs scope o% wor' pertaining to erection, testing * commissioning s all /roadl2 /ut not limited to, t e %ollowing= 1. 2.
(rection, cali/ration >including re-cali/ration c ec's, as re;uired?, testing * commissioning o% instrumentation and control e;uipment. 3n receipt o% instrumentation * control e;uipment at site, Tenderer s all inspect * satis%2 imsel% regarding t e completeness, correctness and ealt o% t e e;uipment as per pac'ing list details. Transportation o% t e e;uipment to t e TendererBs store and: or to respecti&e erection sites along wit t e e;uipment: material re;uired %or t e same. 0ecessar2 &e icles, cranes etc, as re;uired %or t is purpose, s all /e arranged /2 Tenderer in is scope. +ro&iding watc and ward, store'eeper, tec nical * managerial sta%%, as re;uired. Sa%e custod2 o% t e all t e instrumentation * control e;uipment till anding o&er o% t e plant * e;uipment. 8rranging all t e instruments : e;uipment, re;uired %or testing, cali/ration and commissioning o% instrumentation e;uipment at site. 8rranging all %acilities including tools, tac'les, testing instruments, accessories, re;uired %or erection acti&ities at site. Cali/ration c ec's, ad-ustment o% set points and testing o% all t e instrumentation e;uipment prior to installation at site and also during commissioning. $inor ci&il wor's li'e c ipping, digging * grouting %or installation o% supports, stands, panels and c ipping and re%illing o% t e %loors %or conduits. +lugging o% unused : /alance openings in walls, conduits etc.
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3.
4. 5. ". 7. 8. 9.
1!. 11. 12. 13. 14.
Site modi%ications o% panel wiring, i% re;uired. +reparation * installation o% %rames, stanc ions, supports, ca/le tra2s, supporting structures %or conduits * %ramewor' %or installation o% instruments * ca/les. Sealing o% all ca/le entries into t e control room /2 sealing compounds. (art ing o% all instruments, panels, F<s etc to t e near/2 eart /us /ar o% main eart ing s2stem >$(? and screen eart ing to t e (lectronic (art ing S2stem >((?. +ainting o% all impulse lines, ca/le tra2s, structural supports %or tra2s, pipes, -unction /o1es, instruments, ducts etc. and ot er %a/ricated structures re;uired %or instrumentation wor', as per guidelines indicated in General Tec nical @ules * also painting standards %ollowed in t e plant. +unc ing: drilling oles on all panels:ca/inets:enclosures %or ca/le glands. +lugging o% e1tra oles in F.<s, panels, ca/inets etc a%ter completion o% erection. +lugging o% e1tra oles %or conduits a%ter completion o% erection. 5illing up t e conduits * conduit opening wit waterproo% sealing compound a%ter erection. +unc ing: %i1ing o% tag num/ers on metallic plates, on instrumentation e;uipment >w ere&er re;uired?, ca/les, F<s, etc. +urc aserBs re;uirement, i% an2, in t is regard s all also /e complied wit . Construction power at 415 E, 3-p ase, 5!96, will /e made a&aila/le at one point at site. 0ecessar2 distri/ution o% power %rom t is point to meet all t e re;uirements will /e in TendererBs scope along wit t e e;uipment: material re;uired %or t e same. +ro&iding temporar2 lig ting re;uired %or construction wor' along wit t e e;uipment: material re;uired %or t e same. Close co-ordination during installation, testing, pre commissioning * commissioning acti&ities wit ot er associated e1ecuting agencies in t e plant %or ensuring smoot e1ecution o% erection, testing * commissioning o% t e e;uipment under t e scope. $odi%ications including installation * re-installation o% instruments re;uired i% an2, %or proper alignment: installation o% e;uipment, etc., s all also /e carried out. Clearing o% all 'inds o% waste, de/ris, sal&agea/le scrap and unused erection materials resulting due to t e acti&ities o% t e Tenderer at site and t eir disposal: transportation to t e location>s? as decided /2 +urc aser, on a regular /asis to maintain cleanliness at t e wor' places along wit t e e;uipment: material re;uired %or t e same, s all /e ensured /2 Tenderer. Cleaning o% control room on regular /asis is also included in TendererBs scope o% wor' including %inal cleaning o% site /e%ore anding o&er. Heeping proper records o% c anges: modi%ications carried out at site and mar'ing t e c anges in t e wor'ing drawings %or preparation o% as-/uilt drawings.
Page 88 of &29
15. 1". 17. 18. 19.
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+ro&iding ade;uate protection and sa%et2 gears * e;uipment, /oarding * lodging, salaries * allowances, dresses:uni%orms >as applica/le?, %irst aid %acilities, medical treatment, insurance co&erage, etc. %or TendererBs wor'ing personnel, as applica/le, during t eir sta2 * wor' at site. Tenderer s all also arrange %or insurance * ot er statutor2 re;uirements %or is wor' %orce, as per rules. To and %ro transportation o% TendererBs wor'ing personnel %rom t eir place o% sta2 to ContractorBs site o%%ice * &arious sites in t e plant, as * w en re;uired. 0o idle c arges: distur/ance c arges will /e pa2a/le to Tenderer towards site distur/ance: &acation. 8n2 ot er wor' not speci%icall2 mentioned, /ut re;uired %or correctness * completeness o% t e -o/ s all also /e included in t e scope o% Tenderer. I!str(ct o! to Te!'erer Perta ! !" to S(pp-0 Act / t es
2".
27.
::.,
1. 2.
T is tec nical speci%ication %orms a part o% t e tender documents and s all /e read in con-unction wit t e 0otice )n&iting Tender >0)T?. T e instrumentation e;uipment co&ered in t is speci%ication s all con%orm to t e tec nical re;uirements indicated General Speci%ication %or +ower distri/ution, S op (lectrics, )nstrumentation, Telecommunication 7 $(C:GS:A"93:11:(.(CT:!3, @-!, Fanuar2 7 2!!". Tenderer s all ta'e special care in %ul%illing t e instrumentation and control re;uirements including all t e necessar2 e;uipment * accessories essential %or ac ie&ing t e re;uired integrated per%ormance o% measurement and control loops. @e;uirements indicated under )nstrumentation c apter o% GS-!3 >$(C:GS:A"93:11:(.(CT:!3, @-!, Fanuar2 7 2!!"? s all also /e ta'en care o% w ile selecting t e instruments. 8n2 item:component:ser&ice, not e1plicitl2 mentioned in t e Tec nical Speci%ication /ut deemed necessar2 to ma'e t e e;uipment:s2stem complete in all respects %or sa%e * relia/le operation wit guaranteed per%ormance, are included in t e TendererBs scope. Tenderer s all guarantee %or e%%icient * speci%ied per%ormance o% t e instrumentation e;uipment to /e supplied /2 im under t is pac'age. )ncase, an2 instrument is %ound to mal%unction, or %ail to pro&ide speci%ied per%ormance during inspection, testing at site >and also at wor's? and commissioning o% t e s2stem, Success%ul Tenderer s all attend to t e %ault2: de%ecti&e instruments wit in 3 da2s o% reporting o% t e e&ent and ma'e necessar2 repairs: replacements eit er at site or a%ter ta'ing t e de%ecti&e items to wor's, i% necessar2, and send /ac' to site a%ter re;uired action, to t e satis%action o% +urc aser: Consultant, wit out an2 commercial implication. Tenderer s all /e responsi/le %or proper selection o% e;uipment, per%ormance and success%ul operation o% t e complete s2stem, including all /oug t out items * su/s2stems supplied /2 im, w en integrated wit t e automation s2stem.
Page 89 of &29
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7. 8. 9. 1!.
8ll t e %ield mounted instruments under scope o% suppl2 o% t e Tenderer s all /e supplied wit suita/le SS dou/le compression ca/le glands. 8ll t e instrumentation e;uipment s all /e supplied %rom list o% +re%erred $a'es o% (;uipment * Supplies >0o.$(C:A"93.11.37.#3C-!2,@-!, $a2 2!!"? %or $:s 0)0.. 8ll correspondences:documents s all /e in (nglis .anguage and t e data:cali/ration details s all /e su/mitted in $etric or S) Lnits onl2. Tenderer s all su/mit is detailed and complete o%%er including all t e items: e;uipment and ser&ices re;uired as per t is tec nical speci%ication. )n t e e&ent o% TendererBs o%%er not co&ering t e total scope or not completel2 meeting t e tec nical re;uirements, it is lia/le to /e re-ected. Tenderer s all clearl2 indicate t e items, i% an2, e1cluded %rom is scope o% wor' * suppl2, %ailing w ic it will /e deemed t at t e o%%er is in con%ormit2 wit t e re;uirements o% t is speci%ication. Tec nical de&iations, ta'en i% an2, s all also /e clearl2 ig lig ted wit reasons and proposed solution. 8ll necessar2 %acilities including tools, tac'les, testing e;uipment, instruments, accessories, etc. s all /e pro&ided /2 t e Success%ul Tenderer to ena/le inspection o% e;uipment /2 +urc aser: or is representati&e during its manu%acture: %a/rication: assem/l2, testing * inspection. Tenderer s all suppl2 matc ing companion %langes %or all instrumentation e;uipment /eing supplied %or t is pro-ect ta'ing care o% respecti&e application re;uirements. Tenderer s all suppl2 all instruments * accessories new and %rom t e latest product ranges o% manu%acturers. 5or all e;uipment:item prior appro&al o% ma'e * model %rom +urc aser:consultant must /e o/tained wit out w ic t ese s all not /e accepted. +urc aserBs: ConsultantBs decision on an2 Nma'eB * NmodelB in t is regard s all /e treated as %inal * /inding. Selection o% particular ma'e and model o% instruments %or di%%erent units s all /e suc as to permit ma1imum interc angea/ilit2, eas2 maintaina/ilit2 and repair and to maintain minimum in&entor2. T e +urc aser: Consultant reser&es t e rig t o% selecting t e manu%acturer : model o% instrumentation and control items in t e interest o% standardisation w ere&er necessar2 * also to meet application re;uirement, and t e Tenderer s all agree to suppl2 e;uipment accordingl2. Tenderer s all /e responsi/le %or ad erence to all t e applica/le rules, regulations * re;uirements o% statutor2 /odies o% State and Central Go&ernment o% )ndia, as re;uired. T e erection, testing * commissioning acti&ities o% instrumentation e;uipment s all /e carried out /2 competent tec nical persons o% t e Tenderer. )n case, suc ;uali%ied persons are not a&aila/le in ouse, Tenderer s all arrange %or &isits /2 respecti&e instrumentation manu%acturerBs representati&es, as * w en re;uired, and are included in t eir scope.
Page 90 of &29
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17. 18.
19. 0o o% control panels s all /e decided as per t e geograp ical location o% pump ouses * sumps located near /2. T e Tenderer s all indicate t e no. o% panels to /e installed %or t eir s2stem. T e Tenderer s all indicate t e list o% annunciator points to /e located in eac control panel supplied /2 t em.
::.=
Act / t es 1.
I!str(ct o! to Te!'erer Perta ! !" to Erect o!, Test !" < Co## ss o! !" (rection, testing * commissioning acti&ities s all /e carried out as per t e tec nical re;uirements indicated in General Speci%ication %or +ower distri/ution, S op (lectrics, )nstrumentation, Telecommunication 7 $(C:GS:A"93:11:(.(CT:!3, @-!, Fanuar2 7 2!!". )nstructions o% +urc aser or is representati&e, i% an2, s all also /e complied wit . Tenderer s all pro&ide engineers, super&isors, %oremen, s'illed personnel including tec nicians, welders, gas cutters, instrument %itters, riggers, mec anics, licensed electricians, etc., semis'illed and uns'illed sta%%, as re;uired %or t e -o/. Tenderer s all suita/l2 augment is manpower, as and w en re;uired, and s all also wor' on 3 s i%ts per da2 /asis, i% * w ene&er re;uired, to meet t e sc edules. 8%ter placement o% order, Tenderer s all not o%%-load t e contract or an2 part t ereo% to an2 su/-contractor wit out prior appro&al o% t e +urc aser. (&en in t e e&ent o% suc permissions %or su/letting /eing granted, t is will neit er esta/lis an2 contractual relations ip /etween t e appro&ed su/-contractor>s? and +urc aser, nor will release t e Tenderer %rom an2 o% is o/ligations and lia/ilities under t e contract. 8n2 items:components:ser&ices, w ic are not e1plicitl2 mentioned in t e Tec nical Speci%ication or in t e <ill o% $aterial /ut deemed necessar2 to ma'e t e e;uipment:s2stem complete in all respect %or sa%e * proper operation and %or ac ie&ing t e re;uired integrated * guaranteed per%ormance o% measurement and control loops, s all /e in t e TendererBs scope. 8ll erection materials, %ittings * ardware to /e supplied /2 Tenderer s all /e new: %res l2 procured %rom reputed manu%acturers a%ter ta'ing due clearance %rom +urc aser or is representati&es. )n t e case o% an2 wor' %or w ic no speci%ication : guideline is mentioned, t e same s all /e carried out in accordance wit t e rele&ant )ndian: )nternational Standard Speci%ication su/-ect to t e appro&al o% t e +urc aser:Consultant. Co-ordination wit ot er pac'age &endors s all also /e carried out %or completion o% t e -o/. 8ll t e instruments : e;uipment, re;uired %or testing, cali/ration and commissioning o% instrumentation e;uipment, s all /e /roug t to site /2 Tenderer * can /e ta'en /ac' a%ter success%ul completion o% all t e re;uired acti&ities. T ese standard test * cali/rating instruments s all a&e certi%ication %rom standard la/oratories * s all /e periodicall2 updated. Tenderer s all suppl2 all t e erection materials * accessories, re;uired %or installation o% t e instrumentation items.
Page 91 of &29
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(;uipment: accessories %or 2dro testing: pneumatic testing, li'eV pumps, compressors, gauges, regulators, /olts, nuts, temporar2 piping, etc., s all /e /roug t to site /2 Tenderer * can /e ta'en /ac' a%ter success%ul completion o% all t e re;uired acti&ities. 8ll necessar2 %acilities including tools, tac'les, testing e;uipment, instruments, accessories, consuma/les, la/our and super&ision etc. s all /e pro&ided /2 t e Tenderer to ena/le inspection o% wor' at site. Tenderer s all /e responsi/le %or ad erence to all t e applica/le rules, regulations * re;uirements o% statutor2 /odies o% State and Central Go&ernment o% )ndia, as re;uired. Tenderer s all maintain proper records %or receipt and issue o% all materials:items. L st o1 #eas(re#e!ts a!' co!tro-s 1. 8n indicati&e list o% measurements, controls, alarms * interloc's %or water s2stem %or inter plant pipe lines %or %ire water along wit 2drant * ma'e-up water * drin'ing water is gi&en /elow %or compliance /2 Tenderer. 9owe&er, Tenderer s all o%%er all t e measurements, controls, alarms * interloc's as ma2 /e re;uired %or e%%icient * satis%actor2 operation o% t e o%%ered s2stem as per is design * re;uirements and indicate detailed list o% t e same in t e o%%er. $easurements, controls and signaling %unctions s all include, /ut not limited to, t e %ollowing %or eac o% t e units: e;uipment= For each p(#p ho(se )ndication o% pressure >wit snu//er %or surge suppression? at t e disc arge end o% pumps >local?. 5or contaminated %luid, %langed diap ragm seal t2pe pressure gauges s all /e used. <lind t2pe pressure switc >%or low pressure? %or sa%et2 interloc'ing o% low pressure at t e disc arge side o% pumps. 5or contaminated %luid, %langed diap ragm seal t2pe pressure switc es s all /e used. )ndication o% pressure at t e suction side o% pumps >local?. 5or contaminated %luid, %langed diap ragm seal t2pe pressure gauges s all /e used. <lind t2pe pressure switc es in main water line * interloc'ing o% pressure at a preset &alue wit main 2drant pump * -oc'e2 pump operation. 2 nos. pressure switc es s all /e pro&ided on t e disc arge line %or di%%erent preset &alues %or implementation o% &arious interloc's as per process re;uirement. 9owe&er, t e num/er o% pressure switc es re;uired s all /e decided /2 t e Tenderer as per t eir process re;uirement. 5or contaminated %luid, %langed diap ragm seal t2pe pressure switc s all /e used. 8n2 ot er measurement %elt necessar2 %or /etter operation * per%ormance o% t e process. For each s(#p.
Page 92 of &29
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11. 12.
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2. I. 1? 2?
3? 4?
5? II.
1?
Capacitance t2pe le&el switc es %or le&el at eac sump * interloc'ing wit t e pumps operation. 9owe&er, t e num/er o% le&el switc es in t e sump as well as num/er o% le&el points re;uired s all /e indicated /2 t e Tenderer as per t eir process re;uirement. 8n2 ot er measurement %elt necessar2 %or /etter operation * per%ormance o% t e process.
2?
III. Fo--o2 !" sa1et0 !ter-oc8s sha-- 3e pro/ 'e'. / / / / / / #r2 running protection o% pumps in e&er2 sump. 8ll necessar2 interloc's %or control o% pumps * ot er e;uipment. 8ll stand/2 pumps s ould start automaticall2 in case o% tripping o% running pump or pumps %ails to start. Suppl2 * erection o% necessar2 ca/les * ca/le tra2s including ot er erection accessories s all /e included in t e scope o% Tenderer. 8n2 ot er interloc's %elt necessar2 %or /etter operation, sa%et2 * per%ormance o% t e process. 8ll a/normal operating conditions will /e annunciated. Dra2 !"s a!' Doc(#e!ts a a. #rawings and #ocuments to /e %urnis ed <2 Tenderer along wit o%%er= +rocess and instrumentation >+ * )? diagram indicating all local * remote measurements, controls, alarms and interloc' %unctions, using )S8 s2m/ols and suita/le tag num/ers against eac instrumentation e;uipment. <ill o% ;uantities o% all instrumentation e;uipment indicating ma'e, scale range, application * location in ta/ular %orm. Total power re;uirement and also air re;uirement, i% applica/le. T is tec nical speci%ication o% $(C30 wit TendererBs signature * seal on all pages s all /e su/mitted as part o% compliance.
::.6
/. c. d. <. & a. /. c. d. e. %.
#rawings and #ocuments to /e su/mitted /2 Success%ul Tenderer= For A))roval' + * ) diagram using )S8 s2m/ols Speci%ication data s eets s all /e properl2 %illed in * su/mitted wit detailed tec nical literature o% instruments o%%ered. T e rele&ant model no. o% eac instrument o%%ered s ould /e mar'ed on t e tec nical literature. <ill o% ;uantities consolidating loop wise details o% all instrumentation e;uipment indicating ma'e, model no., scale range, application, location in ta/ular %orm. T is s all also include panels * ca/inets, ca/les, electrical accessories. General arrangement drawings o% )nstrument mars alling rac's:ca/inets, )nstrument F<s, etc. wit sectional &iews, dimensional and %a/rication details. Single line power suppl2 diagram wit speci%ications and /ill o% ;uantities o% electrical items * accessories. Aualit2 assurance plan %or instrumentation items.
Page 93 of &29
2 a. /. c. d. e. %. g. . i.
For 2evie3 4 5nformation' Terminal plan, wiring and interconnection drawings %or t e %iled instruments, -unction /o1es, ca/inets, panels, etc. )nstrument ca/le sc edules. #etails o% instrumentation power suppl2 and instrument air >i% applica/le? re;uirement. )nstallation:9oo'-up diagrams. .oop diagrams %or all measurement and control loops. Test, cali/ration and guarantee certi%icates %or all t e instrumentation and control e;uipment. 5unctional write-up. 3peration and maintenance manuals %or all instrumentation and control e;uipment. 5inal 8s-/uilt drawings and documents along wit reproduci/le. I!spect o! Success%ul Tenderer s all su/mit ;ualit2 assurance plan %or eac categor2 o% instrumentation e;uipment, w ic , a%ter %inalisation /2 +urc aser:Consultant, will %orm t e /asis o% inspection procedures to /e %ollowed and complied wit . )nspection call s all /e issued onl2 a%ter ensuring * con%irming complete readiness o% all t e e;uipment:s2stem in compliance wit t e %inali6ed:appro&ed drawings * documents. )nspection calls s all /e accompanied wit internal test, cali/ration certi%icates and material certi%icates, as applica/le. )% +urc aser:Consultant so desires, wai&er o% inspection can also /e decided depending on t2pe o% instrument, completeness and correctness o% test and cali/ration acti&ities as per t e report su/mitted, to t eir satis%action. )nspecting agenc2 reser&es t e rig t to inspect 1!!G o% all t e e;uipment o%%ered or on a selecti&e /asis as per is discretion. )n addition, Success%ul TendererBs responsi/ilit2 s all also include compliance wit %ollowing= t e
::.?
a? /? c? d? e? %? g?
)ssue o% inspection call onl2 a%ter ensuring * con%irming readiness o% total: su/stantial amount o% all t e instrumentation items at one location: $anu%acturerBs premises. $inimum o% 15 da2s prior intimation %or eac inspection. (nsure participation o% competent representati&e o% Tenderer during t e inspection. $a'ing a&aila/le all t e re;uired drawings * documents, catalogues, rele&ant standards, norms, etc. as ma2 /e re;uired %or carr2ing out inspection acti&ities success%ull2. 8rrange and pro&ide %acilities %or test, cali/ration and per%ormance o% eac e;uipment indi&iduall2 * also in integrated mode as per re;uirement. $odi%2: repair: replace de%ecti&e and damaged items: e;uipment, i% %ound during inspection, to t e satis%action o% t e inspector. Su/mit results o% tests, inspection reports etc. in re;uired num/er o% sets to +urc aser:Consultant.
Page 94 of &29
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Pac8 !" < Tra!sportat o!

8%ter recei&ing dispatc clearance %rom concerned aut orities, Success%ul Tenderer s all suita/l2 pac' and transport all t e ordered instrumentation e;uipment along wit t eir accessories * %ittings to t e de%ined destination. T e pac'ing s all ensure ade;uate protection against &i/ration, impact and also ingress o% moisture, water, dust etc. )n case, an2 e;uipment or parts t ereo% are recei&ed at site in damaged condition, Success%ul Tenderer s all arrange %or immediate repairs:replacements wit out an2 commercial implications to +urc aser. 8ll t readed * %langed openings s all /e suita/l2 plugged * protected to pre&ent entr2 o% an2 %oreign material. +ac'ing list in triplicate, indicating /road * ma-or details o% all t e e;uipment, including purc ase order re%erence, addresses o% consignee * manu%acturer: supplier, gross * net weig t and ot er rele&ant in%ormation in sealed * t ic' pol2t ene pac'ets, s all /e securel2 put /ot inside * outside o% eac pac'ing /o1.
::.A
Ge!era- Tech! ca- R(-es

T e %ollowing general guidelines s all /e %ollowed in t e design * selection and erection, testing * commissioning o% t e )nstrumentation e;uipment %or t is pac'age= -
1. 2. 3. 4.
8ll measurements s all /e in metric units. Companion %langes, studs, /olts, gas'ets etc. s all /e supplied along wit t e instruments to a&oid t e c ance o% mismatc . 8ll %ield-mounted instruments s all /e weat erproo% to )+-"5 or /etter. 4etted parts o% instrumentation e;uipment s all /e properl2 selected so as to wit stand p 2sical and c emical properties o% t e process medium. )nstruments wit diap ragm seal t2pe protection s all /e used, i% t e process so demands. )nstrumentation e;uipment to /e installed in corrosi&e atmosp ere s all /e selected to wit stand an2 ad&erse e%%ect. 4 ere&er re;uired /2 t e +urc aser: Consultant, material certi%ication %or suita/ilit2 o% use in t e gi&en process medium s all /e o/tained %rom t e standard: appro&ed la/orator2. Lse o% e;uipment containing mercur2 and ot er to1ic su/stances s all /e a&oided. 8ll instrumentation e;uipment and accessories, including t ose to /e used in control rooms s all /e tropicalised and s all /e o% industrial grade and pro&en ;ualit2. 8ll instrumentation e;uipment s all /e suita/le %or operating continuousl2 under t e en&ironmental conditions indicated /elow=TS for Fire Fighting Facilities !ac"age No. 0#$%
Page 95 of &29
5. ". 7. 8. 9.
5)(.# )0ST@L$(0TS= Temperature = 5 7 55C @elati&e umidit2 = ! 7 1!!G
+80(. )0ST@L$(0TS= 5 7 5!C >minimum? !795G>non-condensing?.
1!.
8ll %ield instruments s all /e pro&ided wit stainless steel tag plates wit t e %ollowing minimum in%ormation engra&ed= )nstrument tag no. $odel no. )nstrument range : set point. )nput:output signal Colour code applica/le %or t e entire plant as per +urc aserBs c oice: rele&ant standard s all /e %ollowed %or instrumentation pipelines, lamps, ca/les, panels, etc. +ainting wor' on all %a/ricated structures * e;uipment s all /e in compliance wit t e standards /eing %ollowed in t e plant. T is will /roadl2 include wire /rus ing, re;uired num/ers o% primar2 coats * %inal paints. 8ll %lange-mounted instruments s all /e pro&ided wit matc ing %langes. <ourdon tu/e >spiral or elical?, /ellows or diap ragm t2pe sensing element s all /e used in pressure gauges: switc es, depending on t e process application. T e gauges s all /e designed in accordance wit )S 3"24. 4 ere&er re;uired, diap ragm seal s all /e pro&ided.
11. 12.
13. 14.
&+. 8ccurac2 s all /e 1.!G o% span %or pressure gauges and 1.5G o% span %or #+ gauges.
8ccurac2 s all include t e com/ined e%%ect o% linearit2, 2sterisis and repeata/ilit2. +ressure switc es s all a&e repeata/ilit2 o% at least 1G o% span.
1".
T e sensing element o% pressure gauges: switc es s all /e a/le to wit stand t e speci%ied o&er-pressure >at least 125 G o% span? %or at least 3! minutes, wit out a%%ecting t eir elastic c aracteristics * per%ormance. T e element and ot er wetted part materials o% pressure gauges: switc es s all /e o% 8)S) 31", unless process media necessitates use o% ot er materials. $o&ement material o% gauges s all /e o% 8)S) 31". 3uter casing and /e6el material s all /e eit er made o% die cast aluminium wit epo12 coating or o% 8)S) 31". +ressure gauges s all a&e e1ternal 6ero ad-ustment %acilit2. T ese s all a&e a linear scale and dial colour s all /e w ite. +ressure gauges s all a&e dial si6e o% 15! mm diameter. Gauges o% smaller dial si6e ma2 /e used %or mac ine- mounting applications.
Page 96 of &29
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2&. +ressure gauges: switc es used in pulsating pressure applications >eg. #eli&er2 side o%
pumps, compressors, etc.? s all /e pro&ided wit e1ternall2 ad-usta/le pulsation dampener or snu//er. 4 ere&er t e process temperature e1ceeds 7! C, pressure gauges: switc es s all /e e;uipped wit 1!! mm pig-tail sip on o% t e same material and sc edule as t e process pipeline.
22.
4indow material o% pressure gauges s all normall2 /e toug ened glass. 9owe&er, w ere t e pressure e1ceeds 4!'g:cm2, window material o% t e pressure gauge s all /e s atterproo% glass. 5or pressure measurement in slurries, &iscous and corrosi&e %luids, diap ragm seals o% suita/le material s all /e pro&ided along wit pressure sensing de&ices. #iap ragm seals s all /e integral wit t e gauges :switc es, unless ot erwise speci%ied. T e sealing li;uid %or diap ragm seal s all /e an inert li;uid compati/le wit process %luid and its temperature. T e wor'ing range o% pressure switc es s all /e selected in suc a wa2 t at t e set pressure is /etween 35G and "5G o% t e range. T e switc enclosure s all /e weat erproo% to )+ "5. #r2 contact t2pe micro-switc es wit minimum rating o% 24!E8C,58 s all /e used %or pressure switc es in non- a6ardous area applications. +ressure gauges * switc es s all /e pro&ided wit 3 7 wa2: 2-wa2 gauge coc's. T ese items s all /e pro&ided in addition to t e isolation &al&es: root &al&es at t e process tapping point. #+ gauges: switc es s all /e supplied wit 3-&al&e mani%olds o% 8)S) 31" material >unless ot erwise speci%ied? o% suita/le pressure and temperature rating. T ese items s all /e pro&ided in addition to t e isolation &al&es: root &al&es at t e process tapping point. )nstrument power suppl2 s all /e single p ase 24! E 8C P 1!G, 5! 96 P 5G. 8ll instrumentation e;uipment s all /e suita/l2 selected accordingl2. Terminals o% 22!E and a/o&e s all /e la/elled and isolated %rom terminals o% lesser &oltages. 8ll electrical s2stems and installations s all meet t e statutor2 re;uirements o% t e )ndian (lectricit2 8ct and rules * regulations o% Central * State Go&ernment. 0o instrument contact s all /e used directl2 %or alarm annunciation or interloc'ing. Contacts a%ter multiplication t roug rela2s s all /e used %or alarms and interloc's. #eri&ation o% necessar2 &oltage grade %rom t e a&aila/le power suppl2, as ma2 /e re;uired %or t e o%%ered s2stem * distri/ution o% power s all /e carried out /2 t e Tenderer. +ower suppl2 e;uipment %or instruments as ma2 /e re;uired s all /e installed inside t e instrument panel.
23.
24. 25. 2".
27. 28. 29. 3!. 31. 32.
Page 97 of &29
33. 34.
8ll signal, control, compensating ca/les * power ca/les %or instrumentation use s all /e o% armoured t2pe. T e conductor s all /e electrol2tic grade tinned copper as per )S 813!= 1984. 8ll ca/les s all /e +EC insulated and +EC s eat ed. )nsulation material s all /e +EC t2pe C and s eat material s all /e +EC t2pe ST2 as per )S 5831= 1984. 8dditionall2, as/estos, silicone or sintered Te%lon s eat s all /e pro&ided in ig -temperature-prone locations. )nstrument power suppl2 and control ca/les s all /e made o% multistranded copper conductor o% 2.5 mm2 o% 1.1 HE grade and ot er details as per )S 1554, +art 1. 5!! E grade ca/les wit multi-stranded, twisted pair copper conductor o% minimum crosssectional area o% 1.5 mm2 s all /e used %or signal ca/les. Ca/le pairs s all /e indi&iduall2 and o&erall s ielded. S ield in screened ca/les s all a&e 25G o&erlap and 1!!G co&erage. S ield s all /e 'ept open at t e instrument end and to /e connected to t e electronic eart pit at t e control room end. T e indi&idual cores in multicore ca/les s all /e +EC insulated * num/ered and: or identi%ied /2 a de%inite colour code. )nstrument panel s all /e %reestanding, %loor mounted, %lus %ront, ca/inet t2pe. +anel dimensions s all /e suita/l2 decided %or mounting o% all t e items and ease o% operation * maintenance. 8ll e;uipment inside t e panel s all /e located in suc a manner t at t eir terminals and ad-ustments are readil2 accessi/le. +anels s all /e dust and &ermin proo%. +anel at %ield s all a&e )+ "5 protection class and t at at control room s all a&e )+ 54 protection class. Suita/le gas'ets s all /e pro&ided, %or t is purpose. 9eig t o% instrument panel s all /e 22!!mm including )S$C 1!! /ase c annel and 15 mm t ic' anti-&i/ration pad on top o% it. )% t e widt o% a panel e1ceeds "!!mm, dou/le-door t2pe construction s all /e pro&ided. 3t erwise, panels s all a&e a single door. 5inal dimensions o% t e panel and its e;uipment distri/ution s all /e as %inalised during detailed engineering stage. +anel s all /e made o% cold rolled continuousl2 annealed steel s eet wit a minimum t ic'ness o% 3 mm %or all load /earing sides and 2 mm %or non-load /earing sides. +anel s all a&e loc'a/le door wit %lus t2pe andle. +anel inside s all /e properl2 illuminated, operating t roug door switc . 3utside colour o% t e panel s all /e gre2 as per s ade no. @8. 7!35, and inside colour s all /e /rilliant w ite. +anels s all a&e li%ting transportation. oo's or e2e/olts on t e top at t e %our corners, %or ease o%
Page 98 of &29
35. 3".
37.
38. 39.
4!.
41.
42.
43. 44.
45.
+anels : ca/inets : des's etc. s all /e supplied in %inis -painted, as per standard practice. T is will /roadl2 include wire /rus ing, sand /lasting, re;uired num/ers o% primar2 coats * %inal paints. T ese s all /e completel2 wired and tested. 5or panel wiring, %or control and signal transmission, multistranded copper wire o% 1.! mm s;. cross sectional area s all /e used. 5or power suppl2 to instruments, multistranded copper conductor o% 1.5 mm2 s all /e used. 4.! mm2 +EC insulated stranded Cu-conductor %or termination on t e eart /us inside panel s all /e used. T e properties and construction o% copper conductors s all /e as per )S=813!-197", w ere as t e p 2sical and electric re;uirements %or +EC insulator and s eat s all /e as per )S=5831-1984. Terminal /loc's s all /e clip-on t2pe o% N(lme1B or e;ui&alent ma'e. 5or signal wiring, 2.5mm2 si6e * %or power wiring, 4.!mm2 si6e terminals s all /e used. 8 minimum o% 2!G spare terminals s all /e pro&ided in eac terminal /loc'. #istance /etween t e edges o% two ad-acent terminal strips s all /e minimum 1!! mm. Separate terminal strips s all /e pro&ided %or 24 E #C, 24! E8C and intrinsicall2 sa%e terminals. +ower suppl2 terminals >e.g. 24!E8C or 24E#C? s all /e la/elled. #istance /etween ca/le gland plates * /ottom o% terminal strips s all /e minimum 3!! mm. )n case a /us /ar is used %or power suppl2 distri/ution, t e /us-/ar s all /e s rouded wit a transparent <a'elite plate. 8ll internal wiring s all /e oused in co&ered, non-%lamma/le plastic racewa2s. Separate wiring racewa2s s all /e used %or power suppl2 wiring, signal wiring and intrinsicall2 sa%e circuitsB wiring. 8n inscription plate >wit w ite letters on a /lac' /ac'ground? containing t e tag no. * application s all /e pro&ided /elow eac instrument : item mounted on t e panel, /ot %ront * inside. +anel s all also a&e identi%ication plate at t e panel %ront top. 3&erall dimensions o% t e nameplates s all /e decided /2 t e te1t o% legend, maintaining o&erall consistenc2 and clarit2 and a&oiding si6e &ariations. +anels or ca/inets s all /e pro&ided wit a power soc'et >o% 24!E 8C, 154 rating? %or soldering, etc., 8 pair o% eart ing /olts inside panel %or power eart ing, 8 copper /us-/ar >o% si6e 2513mm.? mounted on an insulated /ase inside t e panel wit oles and nut-/olts, %or instrument signal eart ing. 5or ca/le routing, ot-dip G) per%orated tra2s o% minimum t ic'ness o% 2.! mm and epo12 painted or %a/ricated tra2 o% $S angle: c annels s all /e used. 5ree ends o% angle support * oles s all not a&e s arp edges and s all /e properl2 rounded o%%. T e widt o% ca/le tra2s s all /e so selected t at 2!G o% tra2 space is a&aila/le %or %uture use o% t e complete installation.
Page 99 of &29
4".
47.
48.
49. 5!.
51.
52. 53.
54. 55.
5".
T e per%orated tra2s s all /e properl2 supported at a regular inter&al o% ma1imum 15!! mm %rom insert plates or steel structures. 8ngle supports %or per%orated tra2s s all /e %a/ricated %rom 4!mm 1 4!mm 1 5mm $S angles minimum si6e. 5or %a/ricated tra2s, support s all /e pro&ided at an inter&al o% 2.! m %or ori6ontal run and 2.5 m %or &ertical run. Conduits used %or ca/le la2ing s all /e as per )S-1239 class medium * gal&ani6ed. 5or ca/le la2ing t roug conduits, pull /o1es s all /e pro&ided w ere&er re;uired. 8ll ca/les and pipes s all /e properl2 tagged wit aluminium tags. 8 clear distance o% minimum 3!!-mm s all /e 'ept /etween instrument and power:signal ca/les. )mpulse pipes s all /e eit er sc . 4!:8! seamless CS pipes >depending on t e pressure rating? as per 8ST$ 81!" Gr.< wit t readed: soc'et weld %ittings or s all /e %ull2 annealed, seamless and cold drawn SS tu/es as per 8ST$ 82"9 wit compression %itting.. Generall2, )mpulse pipe o% XD si6e s all /e used. 9owe&er, %or dust2 application, )mpulse pipe o% YD si6e s all /e used. )mpulse tu/es wall t ic'ness s all /e !.!"5D unless ot erwise speci%ied. )mpulse pipes s all /e pro&ided wit condensate traps, e1pansion loops, 3-piece unions, isolating &al&es, e;uali6ing &al&es, drain &al&es, &ent &al&es, 2-&al&e: 3-&al&emani%olds at suita/le places and s ut o%% &al&es >root &al&es? at tapping points. T e impulse line isolation and drain &al&es s all /e %orged gate: /all: glo/e &al&es wit inside screwed /onnets. CS: SS &al&e material s all /e used depending on re;uirement. $inimum rating o% %ittings s all /e 3!!! pound and &al&e rating s all /e 8!! pound. Function /o1es: (nclosures at site s all /e weat er-proo% to )+ "5. $aterial s all /e o% #ie cast aluminium >.$-" allo2? o% minimum 3 mm t ic'ness. )t s all a&e inged t2pe doors wit door andle. 8ll terminals in F< s all /e suita/le %or accepting minimum 2.5 mm 2 copper conductors. Si6ing s all /e done wit due consideration %or accessi/ilit2 and maintenance. 8ll -unction /o1es s all /e pro&ided wit e1ternal eart ing lugs. Function /o1es: enclosures s all /e pro&ided wit ade;uate supporting:%i1ing arrangement wit nuts, /olts, was ers, /rac'ets etc, as re;uired %or installation on wall :structures. 8ll -unction /o1es s all /e pro&ided wit 2!G spare ca/le entries >minimum 1 no.? and terminals. 8ll spare oles s all /e co&ered wit plugs. 8ll instruments * Function /o1es s all /e supplied wit dou/le compression, SS, weat er proo%, matc ing ca/le glands. 8ll control room panels s all /e supplied wit dou/le compression, SS, weat er proo%, matc ing ca/le glands. Suita/le eart ing pit and eart ing e;uipment * accessories s all /e pro&ided %or power and electronic eart ing o% t e instrumentation s2stem.
Page 100 of &29
57. 58. 59. "!.
"1.
"2.
"3.
"4. "5.
"".
"7.
"8. "9.
$aintenance plat%orms wit inaccessi/le locations.
suita/le approac s all /e pro&ided %or e;uipment %i1ed at
(rection o% instruments s all /e carried out as per t e %inalised instrument installation: oo'up diagrams and ta'ing care o% site conditions. )nstructions o% +urc aser or is representati&e, i% an2, s all also /e complied wit . 5or installation o% an2 'ind o% special t2pe o% instrument: sensor manu%acturerBs recommendation %or installation s all /e %ollowed. #uring erection, testing * commissioning o% critical instrumentation e;uipment and t at %or t e 8utomation s2stem, TendererBs scope s all also include arrangement o% competent tec nical persons o% respecti&e )nstrumentation and 8utomation s2stem manu%acturer at site, as * w en re;uired to meet t e pro-ect sc edule. T e Success%ul Tenderer s all /ring all cali/ration e;uipment, tools, tac'les, welding sets, pipe /ending mac ine, etc., as ma2 /e necessar2 to site, during erection, testing * commissioning. 8ll instruments, /e%ore erection, s all /e cali/rated in t e la/orator2 to /e set up /2 t e Tenderer and records o% suc cali/rations s all /e maintained. T e )nstrumentation e;uipment s all /e cali/rated strictl2 as per standard practice and also ta'ing care o% manu%acturerBs instructions, i% an2. T e scope o% cali/ration s all include all %ield * control room instruments as included in T.S. T e cali/ration %or all instruments s all /e c ec'ed at !G, 25G, 5!G, 75G and 1!!G o% cali/rated span in /ot ascending * descending order. )mpulse pipe s all /e tested 2draulicall2 to 1.5 times t e ma1imum operating pressure using %ilter o% proper mes si6e. #uring %lus ing, pressure testing, steam purging o% main line >process line?, root &al&e at t e starting o% impulse line s all /e closed. #uring 2draulic testing o% impulse line, instrument isolation &al&e s all /e 'ept open to pressurise t e instrument. 5or di%%erential pressure instruments, e;ualising &al&e s all /e 'ept open. 8%ter 2draulic test o% impulse line, t e line s all /e dried up using instrument ;ualit2 air 'eeping t e drain open.
7!. 71.
72. 73. 74.
75.
&2.00 &2.0&
Shop Test !" < Pa !t !" Shop Test !"
12.!1.1 Testing and inspection o% e;uipment, pipes and materials s all /e carried out at t e wor's o% t e Contractor or is su/-Contractor during manu%acturing and on %inal product to ensure con%ormit2 o% t e same wit accepta/le criteria o% Tec nical Speci%ications, appro&ed drawings, aut enticated manu%acturing drawings and re%erence )ndian: )nternational standards.
Page 101 of &29
12.!1.2 T e Contractor s all %urnis Aualit2 8ssurance +lan >A8+? as per t e GS-!5 %or eac e;uipment and material %or (mplo2erBs:ConsultantBs appro&al at least two mont s prior to start o% manu%acturing . 12.!1.3 Tests to /e conducted at t e s op %or &arious assem/lies:su/-assem/lies o% e;uipment s all include, /ut not /e limited to t e %ollowing= i? ii? iii? i&? &? &i? $aterial test. Tests during manu%acture:%a/rication. #imensional c ec'ing. 92draulic test at t e s op. Static:d2namic /alancing test %or all mo&ing parts. +er%ormance test.
12.!1.4 a?
&ii? 8n2 ot er test as re;uired to pro&e t e %unctional re;uirement o% &arious parts o% e;uipment:s2stem. P(#p Tests +ump casings s all /e su/-ected to 2drostatic test at 15!G o% t e s ut-o%% ead or 2!!G o% t e pump rated ead w ic e&er is ig er. T e 2drostatic pressure s all /e eld %or not less t an 3! minutes. )mpeller and pump rotating assem/l2 s all /e d2namicall2 /alanced. +er%ormance tests s all /e carried out on pumps in accordance wit t e code %or acceptance test %or centri%ugal, mi1ed %low and a1ial pumps 7 Class C as per )S 9137 = 1978 >rea%%irmed in 1993?. Tests s all /e carried on eac pump. +er%ormance test s all /e carried out to determine t e %ollowing= i? ii? iii? T e disc arge against t e speci%ied ead w en running at t e speci%ied speed under t e speci%ied suction ead. T e power a/sor/ed /2 t e pump at t e s a%t ><H4? under conditions. 0+S9 re;uired. t e dut2
/? c?
12.!1.5 i?
&a-/e Tests #uring testing t ere s all /e no &isi/le e&idence o% structural damage to
Page 102 of &29
an2 o% t e &al&e components. ii? $otorised &al&es s all /e tested wit t eir actuators, wit a di%%erential ead e;ui&alent to t eir ma1imum wor'ing pressure, to demonstrate t at t e actuators are capa/le o% opening and closing t e &al&es under ma1imum un/alanced ead condition wit in t e speci%ied opening or closing speed. iii? 8ll tests s all /e carried out as per applica/le )ndian: reputed )nternational Standard Codes. i&? T e %ollowing tests s all /e carried out %or /utter%l2 &al&es a? /? c? &? Seat lea'age test at rated pressure. <od2 2drostatic test 1.5 times t e rate pressure. #isc strengt test at /od2 test pressure.
d? Eal&e operation wit and wit out actuator. T e %ollowing tests s all /e carried out %or sluice &al&es a? Seat lea'age test at rated pressure. /? <od2 2drostatic test 1.5 times t e rate pressure. c? Eal&e operation.
&i?
T e %ollowing tests s all /e carried out %or non-return &al&es a? Seat lea'age test at rated pressure. /? <od2 2drostatic test 1.5 times t e rate pressure. c? Eal&e operation.
12.!1." i?
S-( ce Gate Tests Seat Clearance C ec' 4it t e gate %ull2 closed, t e clearance /etween seating %aces w en c ec'ed wit t e t ic'ness gauge, s all not e1ceed !.1 mm. ii? $o&ement Tests
Page 103 of &29
(ac gate s all /e s op operated t ree times %rom t e %ull2 open position to t e %ull2 closed position and return to %ull2 open status, under no %low conditions, to demonstrate t at t e assem/l2 is wor'a/le. iii? .ea'age Tests 4it t e gate in closed position, design pressure s all /e applied %or a period o% not less t an 5 minutes to t e unseating side o% t e sluice gate and t e lea'age s all not e1ceed t e ma1imum lea'age permissi/le as per )S 13349 = i&? 92drostatic Test 8 di%%erential o% one and a al% times t e design pressure s all /e applied to t e unseating side o% t e gate. Lnder t ese conditions, no part o% t e gate s all s ow an2 de%lection or de%ormation.
12.!1.7 i?
P pe Tests Earious tests to /e carried out /2 t e manu%acturer to ensure ig ;ualit2 product s all include, /ut not /e limited to t e %ollowing= a? /? c? d? e? %? ii? Eisual inspection. #imensional c ec'. C emical anal2sis 0on-destructi&e tests $ec anical properties tests. 92drostatic test.
+late and s'elp to /e used %or manu%acture o% pipes s all /e &isuall2 inspected %or an2 sur%ace de%ects. 8ll pipes s all /e &isuall2 e1amined and s all /e %ree o% de%ects in t e %inis ed conditions. #imensional c ec' s all /e made %or outside diameter, wall. T ic'ness, lengt , weig t, straig tness, out-o%-roundness, /e&el angle, /ead eig t, etc.
Page 104 of &29
iii?
T e accurac2 o% all measuring instruments used %or acceptance or re-ection s all /e &eri%ied at least e&er2 operating s i%t. a? T e pipes s all /e su/stantiall2 round. T e di%%erence /etween ma1imum and minimum inside diameters at an2 cross section s all not e1ceed 1G o% t e nominal diameter o% t e cross section under consideration su/-ect to a ma1imum o% 1!mm. Tolerances on outside diameter, wall t ic'ness and straig tness s all /e in line wit t e pro&isions o% )S=3589. +ipe ends s all /e /e&eled as per )S=3589.
/? c? i&?
T e manu%acturer s all %urnis t e result o% c emical anal2sis and mec anical properties tests o% t e pipe material demonstrating con%ormance wit speci%ied limits in )S 3589 =1991.
/5
No!-'estr(ct /e Tests 15G o% t e weld seams o% t e pipes %a/ricated %rom mild steel plates s all /e su/-ected to ultrasonic tests %or crac's, lac' o% complete penetration or complete %usion and discontinuities. )n addition, t e s'elp end weld in %inis ed spiral welded pipe s all also /e inspected.
/5
H0'rostat c Tests a? (ac lengt o% t e pipe s all wit stand, wit out lea'age, 2drostatic test pressure. T e test procedure, pressure and duration o% test s all /e as per t e applica/le standard code. )n order to ensure t at e&er2 lengt o% pipe is tested to t e re;uired test pressure, eac tester s all /e e;uipped wit a recording guage t at s all record t e test pressure and t e duration o% time t e pressure is applied to eac lengt o% pipe, or s all /e e;uipped wit some positi&e and automatic interloc'ing de&ice to pre&ent t e pipe /eing classi%ied as tested until t e test re;uirements >pressure and time? a&e /een complied wit . Suc records or c arts s all /e a&aila/le %or e1amination at t e manu%acturerMB wor's /2 t e (mplo2erMB inspectors.
Page 105 of &29
/?
12.!1.8
5or eac o% t e items /eing manu%actured: supplied, t e %ollowing test certi%icates and documents, as applica/le, in re;uisite copies including original s all /e su/mitted to t e )nspection 8genc2. 8ll test certi%icates s all /e endorsed /2 t e manu%acturer and t e Contractor wit lin'age to t e pro-ect, purc ase order and acceptance criteria. i? ii? @aw materials identi%ication and p 2sical and c emical test certi%icates %or all materials used in manu%acture o% t e e;uipment:pipe. 4elding procedures and welderBs ;uali%ication test Certi%icates, as per applica/le code.
iii? Static: d2namic /alancing certi%icate %or rotating components: mac ines. i&? &? +ressure test certi%icates. +er%ormance tests certi%icates %or all c aracteristics.
12.!1.9 )nspection at manu%acturersB wor's s all not relie&e t e Contractor o% responsi/ilit2 %or replacing at is own cost an2 de%ecti&e part:material and repairing e;uipment %or de%ecti&e wor'mans ip t at ma2 /e disco&ered at site at a later date. 12.2 Shop pa !t !" 8ll t e e;uipments s all /e painted as per t e stipulations o% GTS on painting prior to dispatc . 13.!! 13.1 Pac8 !" < Despatch T e Success%ul tenderer s all pro&ide %or secured pac'ing o% all e;uipment to protect %rom damage during transit %rom point o% manu%acture up to t e site o% erection under conditions w ic ma2 in&ol&e multiple andling, storage and e1posure to eat, moisture, rains, etc. T e Success%ul tenderer s all re%er to t e guidelines in t is regard ass ens rined in GCC. 8ll e;uipment and parts s all /e tagged wit re%erence to t e assem/l2 drawings and corresponding part num/ers /e%ore pac'ing and dispatc . 8ll openings in &al&es, pipes and ot er materials s all /e protected /2 suita/le co&ers or plugs. 8ll pac'ages s all /e clearl2 and properl2 mar'ed in (nglis language wit indeli/le paint /2 stenciling. T e identi%ication mar's indicating t e name and address o% t e
Page 106 of &29
13.2 13.3 13.4
consignee s all /e clearl2 mar'ed on two sides and top o% eac pac'age. Gross and net weig ts, outer dimensions and &olumetric measurements s all /e included in t e mar'ing. (2e /olts, li%ting oo's or /rac'ets s all /e pro&ided %or li%ting t e /o1es, crates and pac'ages. 13.5 (&er2 crate or pac'age s all contain a pac'ing list in a waterproo% en&elope. 8 duplicate cop2 o% t e pac'ing list s all /e sent /2 post to t e (mplo2er. 8ll items o% e;uipment s all /e clearl2 mar'ed %or identi%ication against t e pac'ing list. Cases containing ru//er rings, /olts and ot er small items s all not normall2 weig more t an 5! 'g gross per case. (lectrical e;uipment s all /e enclosed in sealed air-tig t pac'age wit 2groscopic material, /e%ore /eing placed in pac'ing cases on s oc' a/sor/ent materials and secured /2 means o% /attens. T e Success%ul tenderer s all /e responsi/le %or c ec'ing all t e materials deli&ered to t e site and s all 'eep t e (mplo2er %ull2 in%ormed o% t e state o% deli&eries. T e Success%ul tenderer s all carr2 out proper unloading, preser&ation, maintenance, storage and securit2 o% materials deli&ered to t e site. T e Success%ul tenderer s all erect and maintain on t e site an2 temporar2 storage %acilit2 as re;uired and appro&ed /2 t e +urc aser. ERECTION, TESTING AND COMMISSIONING T e erection o% all plant and e;uipment s all /e carried out according to t e latest engineering practices and according to t e drawings, speci%ications, )nstructions etc. dul2 appro&ed /2 t e +urc aser. T e contractor s all carr2out t e wor' in t e presence o% and :or as per t e instructions o% site engineer :super&isor2 personnel deputed /2 t e +urc aser. 9ig l2 s'illed wor'men s all carr2 out t e erection. T e Tenderer s all suppl2 all re;uired manpower, tools and related e;uipment, all oisting e;uipment, all necessar2 sca%%oldings, all necessar2 transporting e;uipment, consuma/les. Construction and erection materials, petrol, diesel oil, Herosene, sol&ents, sealing compound, tapes, /ra6ing and soldering materials, welding and /ra6ing gases, erection /olts, nuts and pac'ing s eets:compounds, temporar2 supports, wooden /loc's, spacers, templates, -ute and cotton wastes, sand:emer2 paper etc. as re;uired %or t e satis%actor2 completion o% wor'. T e Tenderer s all ma'e is own arrangement %or andling t e e;uipment and pipelines at t e stores and transporting it to t e site %or installation.
Page 107 of &29
13." 13.7
13.8
13.9 12.00 :=.:
:=.*
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Grouting o% all e;uipment %rames, /ases, column /olts, etc. to a t ic'ness and re;uirement as s own in t e drawings. 8ll grouting materials >s ims, s rin'omp cement etc.? s all /e supplied /2 t e contractor in ;uantit2 and ;ualit2 as re;uired to carr2 out grouting wor'. T e contractor s all %urnis manu%acturerBs test certi%icates %or supplies o% grouting materials. 8%ter erection, all e;uipment a&ing mo&ing part, su/-ect s all /e gi&en trial operation. T e trial operation s all continuous operation. 8ll modi%ications and recti%ications operation or re;uired %or proper operation s all /e done Tenderer as accepted /2 t e +urc aser. to pressures or &oltages consist o% 24 ours o% re;uired during t e trial at is own cost /2 t e
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+ro&ision o% special tools and tac'les and necessar2 man power %or construction, erection, operation and repair:maintenance o% t e plant and e;uipment. 8de;uate segmentation and interconnections s all /e pro&ided in t e distri/ution networ's to a%%ord ma1imum %le1i/ilit2 o% operation and maintenance. @otating e;uipment s all /e c ec'ed %or proper direction o% rotation and s a%t alignment. (;uipment su/-ect to pressures s all /e care%ull2 e1amined %or lea'age. 8ll e;uipment, suc as pressure taps, temperature measurement connections, %low measurement de&ices etc. s all /e pro&ided /2 t e Tenderer. 3n completion o% t e wor', t e Tenderer s all remo&e and dispose o%% all ru//is and ot er unsig tl2 materials caused /2 is wor'ing to a distance o% %i&e 'ilometer %rom s op area or as directed /2 t e +urc aser and t ere/2 lea&ing t e premises in good, clean, sa%e and opera/le condition. 8ll t e e;uipment s all /e su/-ect to stage inspection /2 t e success%ul TendererBs own inspecting aut orit2 9owe&er, +urc aserBs )nspector ma2 &isit t e wor's %rom time to time w o s all a&e %ree access to all t e places o% t e manu%acturing premises w ere an2 part:parts are under manu%acturer. T e success%ul TendererBs inspecting aut orit2 s all 'eep a close sur&eillance in respect o% t e -o/ %or t e design, dimensions, tolerances, sur%ace %inis etc. <e%ore gi&ing call %or %inal inspection, all t e documents s all /e %urnis ed to t e +urc aser. T e record o% manu%acturing details, inspection and tests carried out /2 t e success%ul Tenderer s all /e made a&aila/le to t e %inal )nspecting 8ut orit2. 9owe&er, appro&al and %inal inspection at t e manu%acturing wor's s all not relie&e t e success%ul Tenderer o% responsi/ilit2 o% replacing at is cost an2 de%ecti&e part : material w ic ma2 /e detected /2 t e purc aser during erection and commissioning or guarantee period. )nspection o% t e item will /e carried out in line wit t e appro&ed A8+ o% t e +urc ase 3rder.
Page 108 of &29
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8ll materials re;uired %or %a/rication, construction, testing and inspection s all /e supplied /2 t e Tenderer. 0o material s all /e %ree issue to t e Tenderer. T e test s all /e conducted at s op %or &arious su/-assem/lies:assem/lies o% e;uipment as per common industrial practices, unless ot erwise speci%ied. (1tent o% testing s all /e %inali6ed during %ormulation o% detailed A8+. 8ll inspection s all /e carried out at t e manu%acturerBs s op:wor's. 0o e;uipment or part item s all /e dispatc ed wit out %inal inspection and issuance o% inspection certi%icate. 8ll e;uipment, assem/lies, su/-assem/lies s all /e s op tested as per rele&ant standards and t e test certi%icates s all /e su/mitted /2 t e supplier. (rection, testing * commissioning o% e;uipments and piping etc s all /e done also inline wit details gi&en in &arious c apters o% GTS. 3/tain necessar2 clearances %rom statutor2 aut orities : state go&t. : central go&t. on /e al% on 0)0.. Erect o! o1 Mecha! ca- E9( p#e!t o1 F re +ater S0ste# T e preparator2 wor' %or installation o% e;uipment included in t is part s all necessaril2 include /ut not /e limited to t e %ollowing = C ec'ing o% all ci&il %oundations : ci&il engineering wor' re;uired %or erection o% e;uipment and accessories. T e %oundations o% all e;uipment s all /e prepared /2 ot er agencies. T e contractor s all satis%2 imsel% t at t e centre line o% %oundation, indi&idual /olt centre, etc, are in accordance wit t e erection drawings. T e contractor s all also ensure t at t e le&els and si6es o% eac %oundation /olt are as per t e instructions o% e;uipment manu%acturer. 8n2 discrepanc2 in t is regard s all /e /roug t to t e notice o% 0)0. : 0)0.Bs representati&e well in ad&ance o% actual erection wor'. 9owe&er, minor recti%ications s all /e carried out /2 t e contractor imsel%. T e contractor s all %ull2 satis%2 imsel% regarding t e correctness o% e;uipment %oundations /e%ore installing t e e;uipment on t e %oundation /loc'. Lnpac'ing, cleaning, assem/ling as re;uired %or all e;uipment and accessories including mounted electrics and instrumentations li'e motors, electric
Page 109 of &29
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actuators, limit switc es, etc, in proper orientation to ena/le eas2 installation : erection on prepared %oundations. !5. !". (rection o% miscellaneous structural wor' suc as supports /rac'ets and clamps re;uired %or e;uipment erection. 0ecessar2 temporar2 plat%orms : sca%%oldings s all /e made and approac s all /e pro&ided i% not a&aila/le %or erection wor'. T ese plat%orms, sca%%oldings, etc. s all /e remo&ed /2 t e contractor a%ter completion o% erection wor'. General conditioning and c ec' 7 up o% all e;uipment including = .u/ricating, oiling and greasing o% all e;uipment and accessories according to manu%acturerBs instructions or as directed /2 0)0. and &eri%2ing t e %ree mo&ement o% mo&a/le parts. )% re;uired, /2 dis-assem/l2 to t e e1tent re;uired to ascertain t at t ere are no de%ects or crac's in an2 parts o% t e e;uipment. Cleaning o% lu/ricants and coating o% parts and %res lu/ricating t ese >e1cepting grap ite rod lu/rication o% /us ings and inged -oints? i% it is %ound necessar2 during inspection. Testing /2 manual operation o% di%%erent mec anisms. C ec'ing o% normal position o% /elt or ot er seals /etween /od2 o% /earings and s a%ts. )% co&ers o% gear reducers, etc, are remo&ed, care s all /e ta'en to see t at t e pac'ings /etween co&er and /od2 do not get damaged. )% pac'ing get damaged, it s all /e replaced /2 new pac'ing similar in t ic'ness and ;ualit2. Static water tan' %or pumps s all /e t oroug l2 cleaned. T e top o% concrete %oundation s all /e t oroug l2 cleaned wit compressed air or air and water -et prior to placing o% /ed plate on e;uipment %oundations. 4 ere opening %or introduction o% grouting materials or &enting as not /een pro&ided, t e contractor s all drill t e re;uired oles as appro&ed /e%ore installation o% e;uipment. 8 su%%icient num/er o% oles s all /e pro&ided %or &enting. <e%ore starting t e erection wor', t e centre lines, /enc mar's, etc. s all /e c ec'ed and esta/lis ed in t e area %or eas2 re%erence. <enc mar's and centre lines are to /e mar'ed on plugs grouted in concrete and protected /2 co&er plates.
Page 110 of &29
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<e%ore putting t e e;uipment into position, top concrete s all /e c ipped o%% and smoot ened %lat w ere pac'ing plates will /e put. Top concrete %oundation s all /e t oroug l2 cleaned onl2 a%ter t is. Erect o! o1 E9( p#e!t, Le/e- !" a!' A- "!#e!t T e contractor s all place t e /ed plates, sole or su/-sole plates on t e %oundations and s im up wit t e mac ined steel plates : wedges until t e e;uipment is in le&el as c ec'ed wit precision le&el instruments. @e;uired mac ined steel wedges and s im stoc's s all /e pro&ided /2 t e contractor and used in su%%icient num/ers to a&oid unsupported spans wit out an2 percepti/le de%lection. T e le&els and alignment o% all installed e;uipment s all /e ensured to wit in tolerance limits as recommended : speci%ied in t e respecti&e manu%acturerBs erection instructions : manu%acturerBs drawings : as directed /2 0)0. : 0)0.Bs representati&e. T e a1es, le&els, alignment and e1pansion mo&ements o% all e;uipment s all /e care%ull2 re-c ec'ed -ointl2 wit 0)0. : 0)0.Bs representati&e a%ter trial operation. 8ll re;uired ad-ustments s all /e made /2 t e contractor as directed /2 t e 0)0. : 0)0.Bs representati&e. 8ll motor dri&en e;uipment s all /e accuratel2 le&eled and aligned to speci%ied tolerances. (;uipment a&aila/le wit mounted motors w ic are aligned and coupled, s all /e re-c ec'ed %or alignment a%ter opening t e coupling. T e contractor s all carr2 out necessar2 welding, gas cutting, grinding wor' as re;uired %or erection : alignment : clearance. .imit switc es, pro1imit2 switc /ases, stri'ers, ot er mounted electrics and instrumentations s all /e mounted on t e e;uipment /2 drilling and tapping oles or /2 welding as per drawings and : or instructions o% 0)0. : 0)0.Bs representati&e. $inor recti%ication wor' on e;uipment : components during erection : assem/l2 : trials s all /e carried out /2 t e contractor at site /2 gas cutting, welding, grinding, drilling and tapping new oles. etc., as a part o% erection wor'. $odi%ication o% /ase %rames : supports %rames o% mounted electrics to t e e1tent o% enlarging : plugging o% oles, drilling and tapping new oles s all /e carried out /2 t e contractor as part o% erection wor'. 5le1i/le couplings, &aria/le speed or &aria/le stro'e dri&es, and guards s all /e installed as supplied /2 t e manu%acturer.
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8ll e;uipment s all /e c ec'ed %or %ree mo&ement /2 and rotation w en correctl2 aligned and installed. 3nce t e e;uipment as /een le&eled and aligned accuratel2 wit respect to re%erence /enc mar' and a1is, a %inal c ec' is to /e made %or %ull tig tness o% anc or /olts wit out distur/ing t e le&el and alignment. )% re;uired, necessar2 corrections are to /e made %or le&el and alignment. 3n completion o% %inal alignment /ut prior to grouting o% e;uipment, an alignment certi%ication indicating measurements : le&els wit re%erence and actual dimensions s all /e prepared /2 t e contractor and s all /e signed -ointl2 /2 im and 0)0.. 8%ter t is, grouting s all /e done so as to solidl2 %ill t e &oid /etween t e /ottom side o% t e e;uipment and roug %oundation so t at t e e;uipment is %irml2 eld in its original aligned position. T e grouting s all /e done t e same da2 t e alignment o% t e e;uipment is completed and c ec'ed. 4 en t e grout as /een t oroug l2 cured, t e alignment s all /e-re-c ec'ed and recti%ied, i% re;uired. Suita/le mac ine pac'ings s all /e used %or o/taining accurate alignment o% t e mec anism. 8ll loose pac'ings s all /e tac' welded a%ter alignment. T e contractor s all install couplings o% e;uipment to speci%ied manu%acturerBs tolerances and appro&al s all /e o/tained %rom 0)0. : 0)0.Bs representati&es /e%ore %inal coupling o% t e e;uipment is completed. 4 en t e alignment o% couplings as /een %inall2 c ec'ed and appro&ed /2 0)0. : 0)0.Bs representati&e a%ter satis%actor2 trial run ,t e contractor s all drill and ream oles %or taper pin dowels pro&ided and install t e mac ined dowels as re;uired. Couplings s all /e disassem/led and recoupled as re;uired during t e trial runs o% an2 e;uipment and its dri&es. 8ll gears s all a&e an eas2 run. 8%ter /o1ing up to t e dri&e, a c ec' s all /e done %or %reeness. )nstallation o% al% coupling o% s a%ts s all /e c ec'ed /2 scri/ing /loc' or dial indicator %or eccentricit2 or misalignment. 4 ile rotating t e s a%t, radial di&ision and %acial misalignment o% t e s a%t coupling s ould not /e more t an !.1 mm. )n case o% gear couplings, e1treme care s all /e ta'en to %it all oil seals, c ec'ing o% tig tness o% %ittings o% al% couplings on s a%t s ould /e as per t e drawing. T is s all /e c ec'ed /2 %eeler gauge.
Page 112 of &29
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)nstallation o% /us ing, pulle2s, gears, etc. on s a%t s all /e c ec'ed %or correctness. +ac'ing, S ims, etc. = +ac'ing plates, taper wedges in +airs, s ims, etc. used %or le&eling t e e;uipment to maintain t e re;uired le&els as per t e drawings s all /e supplied /2 t e contractor. +ac'ing plates to /e used %or le&eling and ad-ustment s all /e o% suita/le material as recommended /2 0)0. : 0)0.Bs representati&e or cut %rom steel plates into si6es &ar2ing %rom 2!! to 3!! mm in lengt , 5! to 1!! mm in widt and 2! to 1!!mm in eig t. #epending upon t e weig t o% t e e;uipment. 8ll pac'ing plates a/o&e 1! mm t ic' small /e mac ined on /ot sides, +ac'ing plates 1! mm t ic' and /elow s all /e de/urred and and ground /e%ore using. Taper wedges s all /e mac ined wit a slope o% 1=5!. S ims %or %inal le&eling s all /e c osen %rom 3 to 1! mm strips. S ims s all also /e 'ept read2 %rom &arious t ic'ness o% cold rolled s eets. +ac'ing plates s all /e placed closed to t e %oundation /olts and at /ot sides o% t e /olts e1tending upto t e diameter o% t e /olts, #istance /etween t e two pac'ing s all not /e more t an "!! mm.
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$iscellaneous Clearance o% 5! to 1!! mm s all /e maintained /etween t e roug concrete and /ottom o% e;uipment /ase plate depending upon t e weig t o% e;uipment. T e clearance s all /e maintained %or di%%erent e;uipment as per ci&il drawings. 8ll motors s all /e aligned and coupled wit t e e;uipment properl2. T e proper alignment /etween t e motor and t e e;uipment s all /e determined /2 use o% dial indicator. 8ll mounted electrics and piping on t e e;uipment proper s all /e installed /2 t e contractor. @igging, site %ittings, si6e assem/ling, re&etting, /olting, welding, gas cutting, drilling, tapping and installation o% all e;uipment and %a/ricated materials s all /e solel2 as per drawings : direction o% 0)0. : 0)0.Bs representati&e.
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#rilling and reaming o% dowel oles and %itting o% dowel w ere&er necessar2 s all /e done /2 t e contractor. Cleaning o% %oundation /olt ole poc'ets and redressing o% %oundation /olt : nut t reads, i% necessar2, %or eas2 %itting and erection s all /e done /2 t e contractor.
!". 8ll correcti&e measures, i% re;uired, s all /e carried out /2 t e contractor and e;uipment s all /e o%%ered %or re-c ec' to 0)0. : 0)0.Bs representati&e. !7. T e anc or /olts are tig tened ensuring t at t e pac'ing plates and s ims are solid. #uring %inal alignment o% t e e;uipment, t e s im pac's s ould /e c ec'ed %or tig tness. .e&eling screws s all /e released /e%ore tig tening o% %oundation /olts. !8. 8%ter proper setting, t e e;uipment s all /e connected to t e s2stem networ' li'e ser&ice pipeline, duct, electricals, etc. %or integrated commissioning. !9. 8rrangement %or pipe la2out s all /e suc as to protect t em against t e material %alling t roug e;uipment. !1!. T e contractor s all /e responsi/le %or drilling and tapping oles on t e e;uipment %or installation o% ducting and piping, i% re;uired. !11. T e contractor s all /e responsi/le %or 'eeping t e structures, materials or e;uipment ade;uatel2 /raced /2 gu2s : struts or ot er appro&ed means during erection. !12. 8%ter t e e;uipment as /een le&eled, aligned and grouted, and t e alignment needs to /e re-c ec'ed due to some discrepanc2 in alignment o% connected electrical dri&e, t en t e same s all /e carried out /2 t e contractor. )n case o% an2 discrepanc2, all recti%ications s all /e carried out /2 t e contractor. !13. T e contractor s all clean t oroug l2 all t e parts to t e assem/led, lu/ricate * reassem/le. 8ll dowelling, w ere&er necessar2, s all /e done /2 t e contractor. !14. T e tests : c ec's to /e conducted during erection s all /e as per t e instructions o% 0)0.. T e contractor s all attend to all recti%ications o% erection de%ects. !15. T e contractor s all underta'e radiograp ic : ultrasonic : d2e penetration testing and stress relie&ing o% welds as per erection instructions and speci%ications. !1". T e contractor s all couple t e electrical motor to t e mec anical dri&e and also align and le&el t e electrical e;uipment mounted on mec anical e;uipment. !17. Certain electrical items s all /e a&aila/le at site dul2 assem/led wit mec anical e;uipment. T e contractor s all arrange %or t eir erection, testing and commissioning.
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!18. 5lus ing, %irst %illing and su/se;uent topping up o% oils and lu/ricants, w ere&er necessar2 s all /e carried out /2 contractor. !19. T e contractor s all carr2 out an2 dismantling, re-assem/l2 and re erection o% pre&iousl2 erected e;uipment, i% so re;uired, on account o% reasons li'e de%ecti&e erection wor' or due to o&erall re;uirements o% su/se;uentl2 erected e;uipment. T e contractor s all ensure t at t e le&el, a1es, etc. /ased on w ic e is aligning t e e;uipment are aut enticated and as suc wor' will /e minimum. T e contractor s all not claim e1tra %or an2 suc re-wor'. !2!. T e contractor s all carr2 out an2 dismantling and re-assem/l2 o% erected e;uipment t at ma2 /e re;uired due to un%oreseen reasons. T is acti&it2 ma2 a&e to /e carried out more t an once due to site re;uirements. :=.*, :=.*,.: +reliminar2 8cceptance Test >+8T? o% water suppl2 e;uipment 8%ter completion o% erection o% water suppl2 e;uipment, 0)0.:0)0.Bs representati&es -ointl2 wit t e contractor s all per%orm +8T to %ind out w et er t e e;uipment : s2stems as /een properl2 erected as per t e appro&ed erection drawings instructions o% 0)0. and 0)0.Bs representati&es:respecti&e manu%acturerBs instructions and manuals. T e de%ects o/ser&ed in erection wor':recti%ication wor' re;uired s all /e listed out -ointl2 and t e de%ect list s all /e dul2 signed /2 all concerned. T e contractor s all attend:recti%2 all o/ser&ations o% de%ect list point wise and s all dul2 in%orm 0)0.:0)0.Bs representati&es are %ull2 satis%ied regarding t e proper erection o% t e s2stem and suita/ilit2 %or operation o% t e s2stem. 0)0. s all issue a +8T certi%icate to t e success%ul contractor. T e detailed procedure : %ormat o% +8T s all /e %urnis ed /2 t e success%ul contractor %or appro&al o% 0)0.:0)0.Bs representati&e. T e issue o% +8T certi%icate s all in no wa2 relie&e t e contractor %rom is contractual o/ligation and guarantee %or correct erection:smoot operation o% t e s2stem. 5ollowing general c ec's s all /e made %or all e;uipment during +8T = !1. !2.
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Smoot running o% all e;uipment and occurrence o% an2 a/normal sound. 8lignment and le&eling o% all e;uipment
Page 115 of &29
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+ressure testing: 2draulic testing as re;uired 5irst %illing o% grease and lu/ricants C ec'ing t e direction o% rotation o% electrical motor /e%ore coupling 0o load running:mo&ement o% all mo&ing e;uipment C ec'ing %oundations:grouting and /olt tig tness 3&erall dimensional c ec'ing and ad erence to appro&ed drawings:manu%acturerBs instructions C ec'ing o% temperature rise in motor Ei/rations:sta/ilit2 o% supporting structures Erect o! o1 p pe- !es o1 +ater S0ste# 8ll elements o% t e pipeline s2stem s all /e erected at site strictl2 as per t e drawings appro&ed /2 t e 0)0.:0)0.Bs representati&e. 8n2 modi%ication to /e carried out at site, s all a&e t e prior appro&al o% 0)0.:0)0.Bs representati&e. 4 ile erecting, pipelines s all rest uni%orml2 on eac support. Ko'es, i% pro&ided, s all not allow lateral mo&ement o% pipes. $atc ing %aces o% %langes s all /e perpendicular to t e a1is o% pipelines. Lse o% gas'ets o% unusual t ic'ness to %ill gap /etween %langes s all not /e allowed. 5or ori6ontal pipes, t e %langes s all /e erected suc t at top two /olt oles are displaced /2 al% pitc %rom t e &ertical a1is o% t e %lange. 5langes o% ad-acent pipes s all /e located in staggered manner. )n case t e location o% spindle w eel o% &al&es in not clearl2 s own in t e erection drawings, t e same s all /e located in a manner as to %acilitate eas2 operation %rom ground le&el or nearest operating plat%orm.
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5or ma'ing pipe /ends : el/ows at site using ot : cold /ending process, t e decrease in t e pipe t ic'ness s all not /e more t an 15G o% t e pipe t ic'ness. 8%ter erection o% pipelines, an2 oles made in t e walls s all /e co&ered wit /ric's * mortar. 8 gap o% 1! to 2! mm s all /e 'ept /etween wall and t e pipe %or t e mo&ement due to t ermal e1pansion. T e gap s all /e %illed wit %elt : as/estos. T e contractor s all /e responsi/le %or t e preparation o% detailed erection mar'ing plans, drawings %or pipe supports and all necessar2 lists suc as indents, /olt lists, pac'ing lists, all /oug t out items lists, etc. %rom in%ormation %urnis ed /2 0)0. in t e design drawings. 8ll modi%ication drawings prepared /2 contractor s all /e appro&ed /2 0)0. : 0)0.Bs representati&e. Eo ! !" o1 p pe- !es 4elded -oints = 8ll $S pipes o% si6es #0 "5 and a/o&e will a&e welded -oints. 8ll pipe sections s all /e -oined /2 welding /2 using plain ended pipelines %langed -oints s all /e used onl2 %or connecting t e pipe wit e;uipment, &al&e or %itting. (lectric are welding s all /e used %or -oining pipes, supports, structures, etc. 8ll manu%actured pipes s all /e -oined /2 /utt welding. .arge dia pipes, %a/ricated %rom s eets, s all /e -oined /2 %illet welding using semi-/andages attac ed to eac section /eing -oined. 4elding s all /e done /2 ;uali%ied welders. Code o% practice as per rele&ant )ndia Standards s all /e %ollowed %or t e welding procedure, use o% electrodes etc. +roper edge preparation and pre eating o% edges to /e welded, w ere&er re;uired, s all /e ensured /e%ore welding. Screwed Foints 8ll G) pipes o% si6es upto #0 15! will a&e screwed -oints. +ipe sealant s all /e used to ma'e up screwed -oints and s all /e applied to male t read onl2. T readed parts s all /e wiped clean o% oil and grease using appropriate sol&ent, i% necessar2 and allowing proper time %or dr2ing /e%ore appl2ing t e sealant
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pipe s all /e %ree %rom %ins and /urrs. +ipe ends s all /e reamed or %iled out to si6e /ore and all c ips s all /e remo&ed. :=.*6 :=.*6.: Tre!ch 2or8, 3ac8 1 -- !" a!' 2rapp !" o1 (!'er "ro(!' p pe- !es. 5or /uried pipeline, e1ca&ation, suppl2 o% wrapping, coating materials, application o% coating materials, la2ing and /ac'%illing are included in contractorBs scope o% wor'. (1ca&ation o% Trenc es = Trenc e1ca&ation s all include t e remo&al o% all materials including t e aul o% e1cess material to disposal area and usa/le material to stoc'pile area upto a distance o% 1 'm. (1ca&ation in /ot common and roc' material s all /e carried out to t e lines and grads s own on t e drawings, unless ot erwise speci%ied. )n t e e&ent t at trenc is constructed to widt or dept greater t an t at permitted a/o&e, t roug contractorBs error, t e contractor s all %urnis t e necessar2 material, la/our and e;uipment to correct suc error as decided /2 0)0. : 0)0.Bs representati&e. S oring and /racing s all /e used to support t e walls o% trenc es w ere&er necessar2 to protect li%e and lim/s o% wor'ers. 4 en closed s eeting is re;uired, it s all /e so dri&en as to pre&ent ad-acent soil %rom entering trenc es eit er /elow or t roug s eeting and /racing s all /e remo&ed a%ter t e2 a&e ser&ed t eir purpose. $inimum eart co&er o% 1.2 metre s all /e pro&ided a/o&e t e pipe %or all underground piping. :=.*6., #isposal = (1ca&ated materials deemed suita/le /2 0)0.:0)0.Bs representati&e %or an2 purpose s all /e stoc'piled in re;uired ;uantities in t e &icinit2 o% t e e1ca&ation sites in&ol&ed, as per t e appro&al:directions o% 0)0.:0)0.Bs representati&e, upto a lead o% 1!!!@$. Lnsuita/le or e1cess e1ca&ation material and de/ris s all /e transported to spoil areas as directed and appro&ed /2 0)0.:0)0.Bs representati&e. $aterial s all /e end dumped and graded at t ese areas.
:=.*6.*
:=.*6.= !1.
+rotecti&e coating %or underground mild steel piping = Lnderground mild steel pipes s all /e wrapped and coated generall2 as per )S=1!221 7 1982 >@ea%%irmed in 1991? >Code o% practice %or coating and wrapping o% underground mild steel pipelines? and as per t e %ollowing procedure.
Page 118 of &29
!2. s ould /e 2dro-tested. !3. !4.
<e%ore appl2ing t e tapes, t e pipes T e pipe sur%ace s all /e cleaned /2 wire /rus ing %or remo&al o% loose scale, rust, dirt, %oreign de/ris etc. 8 single coat o% coal tar * sol&ent /ased primer a&ing a densit2 !.9 to !.95 gm:cm3 s all /e applied /2 /rus to gi&e a t in continuous coating o&er t e area to /e protected. 8pplication o% %actor2 made wrapping tape o% minimum 3 mm t ic'ness s all /e pro&ided %or pipe si6es upto #0 15!. 5or si6es #0 2!! and a/o&e, 4mm t ic' tapes s all /e pro&ided. T e tapes s all /e wound spirall2 using t ermo %usion o&er t e sur%ace o% pipe wit a minimum o&erlap o% 25 mm. )t s all /e ensured t at t e tape is in contact wit t e underl2ing sur%ace and no wrin'les o% air poc'ets are %ormed. +ipes wrapped wit /e olida2 tested /e%ore lowering into trenc es. <ac' %illing = <ac'%ill s all contain no as es, ru//is , com/usti/le or decomposa/le material, not an2 ot er material w ic 0)0.:0)0.Bs representati&e deems unsuita/le %or t is purpose. )% t e e1ca&ated material is deemed unsuita/le /2 0)0.:0)0.Bs representati&e %or use as /ac'%ill, t e contractor s all /ac'%ill wit material appro&ed /2 0)0.:0)0.Bs representati&e w ic s all /e o/tained %rom locations to /e speci%ied. +rior to t e lowering and la2ing o% pipe in an2 trenc or e1ca&ation, t e contractor s all /ac'%ill and compact t e /ottom o% t e trenc or e1ca&ation to pro&ide as accepta/le /ed %or placing t e pipe. )% roc's or ot er ard o/-ects occur in t e /ac' %ill along an2 section o% t e pipeline, suc /ac' %ill material s all /e screened /e%ore /eing placed around t e pipe or at t e option o% t e contractor, suita/le /ac' %ill %rom ot er places ma2 /e transported to and placed around t e pipe in suc section. Settlement o% /ac' %ill in t e trenc s all /e /2 means o% %looding, puddling, tamping or -etting onl2. +o'ing wit metal rods will not /e permitted. <ac' %illing s all /e conducted at all times in suc a manner as to pre&ent damage and a/rasion to coal tar protection on pipe.
Page 119 of &29
!5.
!". :=.*6.> !1.
tapes s all
!2.
!3.
!4.
!5.
+lacing o% /ac'%ill a/o&e t e protected pipe s all /e done a%ter conduction o% all necessar2 tests onl2 in t e presence o% 0)0.:0)0.Bs representati&e a%ter is %inal inspection and acceptance. Erect o! o1 /a-/es a!' 1 tt !"s <e%ore erection o% &al&es, coc's and ot er %ittings w ic are to /e mounted on pipelines:e;uipment s ould /e dismantled, onl2 i% re;uired, cleaned, oiled and reassem/led. Glands s all /e pac'ed wit suita/le materials as per appro&ed drawings. 8ll mo&ing parts o% t e pipe %ittings s ould mo&e %reel2 wit out -amming. Eal&es s all /e tested 2draulicall2 : pneumaticall2 %or lea'age /2 appl2ing pressure on upstream side wit &al&e in closed position <olts and nuts s all /e cleaned and lig tl2 oiled. +roper grades o% gas'ets s all /e used %or erection as per appro&ed drawings. Test !" o1 P pe- !es +reliminar2 acceptance test %or erected pipelines s all /e carried out as %ollows = C ec'ing o% pipelines as per manu%acturerBs certi%icate : appro&ed drawings. Eisual e1amination o% welds. #imensional c ec's as per t e appro&ed erection drawings. C ec'ing o% welded -oints /2 c al' and 'erosene test. 92draulic test = +ipelines %or li;uid ser&ices a%ter erection s all /e 2draulicall2 tested /2 water at 1! /ar >g? or 1.5 times ma1imum s2stem pressure w ic e&er is ig er as per stipulation o% drawings. 5or carr2ing out 2draulic tests, t e erection Contractor s all arrange testing e;uipment li'e tan's, pumps, temporar2 pipes, &al&es at is cost.
Page 120 of &29
:=.*? :=.*?.:
:=.*?.* :=.*?., :=.*?.= :=.*?.> :=.*@ :=.*@.: !1. !2. !3. !4. :=.*@.* !1.
!2.
+ipelines s all /e 'ept pressuri6ed until t e entire section, under test, as /een e1amined %or lea'age. 9owe&er, minimum duration %or 'eeping pipes under 2drostatic pressure s all /e 4 ours. #e%ects re&ealed /2 t e tests s all /e repaired or de%ecti&e parts replaced and t e s2stem s all /e retested. 4elded -oints s all /e su/-ected to and ammer test w ile under test pressure. C ec'ing o% proper installation o% supports, e1pansion -oints, &al&es * %ittings. Testing +rocedure T e pipeline or section t ere o% under testing s all /e slowl2 %illed wit water and t e test pressure measured at t e lowest point o% ele&ation, s all /e applied /2 means o% pump. T e duration o% eac pressure test s all /e %our ours, and s all /e as per t e rele&ant standards. #uring t e test period t ere s all /e no drop in pressure in case o% 2draulic tests and ma1imum o% 1 per cent pressure drop in case o% pneumatic tests %or air lines and gas lines a%ter temperature corrections. 4 ile a line is under pressure all &isi/le lea's s all /e pre&ented /2 tig tening w ere&er possi/le. 3t er t2pe o% de%ecti&e -oints s all /e cut and replaced. 8n2 crac'ed or de%ecti&e pipe, %itting, &al&e etc. s all /e remo&ed and replaced /2 contractor wit sound material and t e test s all /e repeated until t e results are satis%actor2. #e%ecti&e welds s all /e repaired /2 remo&ing t e de%ecti&e piece o% pipe w ic caused t e lea' and rewelding. 0o weld lea's s all /e repaired /2 mec anical caul'ing. T e contractor s all arrange pumps, /arrels, tan's /ul' eads, /lan's, connections, test gauges and all ot er e;uipment necessar2 %or pressure testing. Compressed air s all /e arranged /2 t e contractor t roug porta/le air compressors. T e contractor s all %urnis , install and dismantle all temporar2 lines to t e s2stem under test. T e contractor s all conduct all tests and 'eep proper records o% all test, dul2 certi%ied /2 t e (ngineer. Ealues o% line pressure and temperature as well as am/ient conditions s all /e ta'en at eac NreadingB. T e inter&als /etween t e successi&e readings s all /e 3! minutes unless ot erwise directed /2 t e site engineers o% 0)0. : 0)0.Bs representati&e. Tested pressure gauges, temperature indicators etc. s all /e used in duplicate %or tests.
!3. :=.*@., !1.
!2.
!3.
!4.
Page 121 of &29
!5.
T e s all arrange water %or testing o% water piping s2stem /e%ore installation.
contractor
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:=.*A :=.*A.: :=.*A.* ):.
F-(sh !" o1 P pe- !es +ipelines %or water s2stems s all /e %lus ed wit water to remo&e all de/ris, dirt, rust particles, etc. )nitial 5lus ing T e %ollowing s all /e planned and done /e%ore initial %lus ing =
a. Earious t2pes o% control &al&es, etc. s all /e remo&ed and %itted wit distance pieces. T e a/o&e %ittings will /e %lus ed and cleaned manuall2. 8ll water pumps strainers etc. s all /e isolated during %lus ing and cleaning operation. /. 8ll t e pumps and e;uipment in t e cleaning circuit s all /e isolated /2 /lan'ing and /2 passing t roug temporar2 connections on t e pipeline. )% strainers are 'ept in t e main circuit during %lus ing operation, t ese will /e remo&ed, cleaned and re%itted a%ter %lus ing is completed. c. T e pipes not coming in direct circulation s all /e dismantle and %lus ed separatel2 /2 ma'ing suita/le closed ring. :=.,) :=.,).: :=.,).* :=.,)., :=.,).= :=.,).> :=.,: :=.,:.: Co## ss o! !" o1 P pe- !es 8ll pipelines s all /e commissioned onl2 a%ter success%ul completion o% acceptance tests, strengt tests and lea'age tests. 8ll &al&es and regulating de&ices s all /e c ec'ed %or proper operation. 8ll sa%et2 relie% &al&es s all /e c ec'ed and set at re;uired pressure setting. 8ll instruments, interloc's etc. s all /e c ec'ed. 8%ter c arging t e water into t e s2stem, all isolating de&ices, controlling de&ices, instruments, air release &al&es, etc. s all /e again c ec'ed %or proper operation. Respo!s 3 - t0 1or E9( p#e!t 8%ter t e contractor as supplied and erected t e s2stem, e s all /e responsi/le %or t eir sa%et2 and protection %rom loss or damage o% an2 nature until t e plant is %inall2 anded o&er to 0)0.. Surplus materials and e;uipment are to /e accounted %or and are to /e anded o&er to 0)0.. )denti%ication and records o% t e materials recei&ed and installed s all /e maintained /2 t e contractor. T e materials to /e ta'en out o% t e pro-ect site s all /e in consultation and appro&al o% aut ori6ed personnel o% 0)0..
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:=.,:.*
$anu%actureBs Special Tools T e contractor will /e allowed /2 0)0. on case to case /asis to ma'e %ull use o% special tools, i% an2, supplied /2 t e manu%acturer o% e;uipment. T e contractor s all return all suc tools to 0)0. on completion o% t e wor' in a ser&icea/le condition.
:=.,* :=.,*.:
Metho' o1 +or8 T e contractor s all adopt met ods and procedures o% wor' to suit t e nature o% wor' in&ol&ed and is own e1perience in suc wor'. 9e s all owe&er ta'e t e appro&al o% 0)0.:0)0.Bs representati&e w ere necessar2 %or t e procedures and met od o% wor' proposed to /e adopted. Pro"ra##e o1 2or8 T e contractor s all sc edule is wor' to meet t e speci%ied targets and ensure t at drawings, materials, e;uipment and ser&ices re;uired are re;uisitioned well in ad&ance %or t e re;uirement at site, so as to meet t e demands o% t e construction sc edule. #ela2s w ic ma2 a%%ect t e progress o% wor' s all /e /roug t immediatel2 to t e notice o% 0)0. in writing. T e contractor s all resc edule t e wor' and:or per%orm o&ertime wor':deplo2 more manpower at is cost as ma2 /e necessar2 to meet t e re;uired construction +rogramme. Stora"e a!' Ha!'- !" General= T e contractor s all pro&ide ade;uate storage s eds w ic are to /e wind and watertig t %or t e storage o% e;uipment &i6. pumps, &al&es, insulation materials, welding materials, electrodes, etc. to protect t em %rom damp and moisture. 8ll au1iliar2 and loose parts s all /e s2stematicall2 classi%ied %or read2 identi%ication and location w en needed. 8s %ar as possi/le, materials s all /e stored in t e order re;uired %or installation. T e contractor s all care%ull2 inspect all materials and e;uipment a%ter receipt o% t e same %or completeness and concealed damages and report an2 s ortages or damages to 0)0. %or e1amination and ad&ice on an2 remedial measures to /e ta'en. T e contractor s all arrange proper andling e;uipment e.g. tower cranes, mo/ile crane, oists, winc es, derric's, slings, c ain pulle2 /loc's, 2draulic -ac's, dewatering pumps, etc. 8ll e;uipment and rigging s all /e e1amined and c ec'ed at %re;uent inter&als to pre&ent accidental %ailure and damage to t e e;uipment to /e installed. T e contractor s all maintain at all times an up to7date card inde1 o% all receipts and issues o%
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:=.,, :=.,,.:
:=.,= :=.,=.: !1.
!2.
!3.
!4.
:=.,=.* !1.
materials and e;uipment and /e accounta/le %or it till andling o&er o% all le%to&er materials to 0)0. a%ter completion o% wor'. (;uipment Storage Lpon receipt o% materials, t e contractor s all ma'e a care%ul c ec' o% all e;uipment and appl2 protecti&e grease and wrappings, i% necessar2 on mac ined sur%ace or ot er parts as necessar2 to protect t em during storage. 8n2 s ort%all a%ter receipt o% material s all /e made up /2 t e contractor. @eciprocating and : or rotating e;uipment recei&ed completel2 assem/led s all, w en necessar2, /e lu/ricated and tuned manuall2 as o%ten as directed /2 0)0. and :or according to t e instruction contained in t e manu%acturerBs instruction /oo's to pre&ent sei6ing and locali6ed pitting. )nsulation $aterials 8ll insulation materials s all /e care%ull2 andled and s all /e protected %rom moisture. 9ig medium, and low temperature insulation materials s all /e care%ull2 andled to pre&ent damage and all damages will /e made /2 t e contractor. +ipes and Tu/es +ipes s all /e care%ull2 unloaded and s all not /e dragged or li%ted %rom t eir ends. (nds o% pipes and t e openings o% all %langes and no66les attac ed to drums, tan's or e;uipment w ile in storage s all /e greased, capped plugged or /lan' %langed, w ic s all /e at t e contractorBs cost. T e co&ering s all /e done in a manner to pre&ent ingress o% an2 %oreign matter. T e contractor s all pro&ide all re;uired support to store suc materials at su%%icient eig t a/o&e ground to pre&ent corrosion. +ipes o% di%%erent t ic'ness and materials s all /e stored separatel2 %or suita/le identi%ication. T e identi%ication mar's pro&ided /2 t e manu%acturer s all /e c ec'ed and an2 dis%igured or o/literated mar's s all /e renewed as directed /2 0)0.. Eal&es and 5ittings T e contractor s all c ec' t at &al&es and %ittings are not su/-ected to corrosion. 8n2 suc condition w en detected s ould /e /roug t to t e notice o% 0)0. and remedial measures ta'en as directed. (nds o% all &al&es and %ittings s all /e greased and 'ept plugged or capped suita/l2. #i%%erent si6es and categories o% materials s all /e stac'ed separatel2 wit identi%ication tag.
:=.,=., !1.
:=.,=.= !1.
:=.,=.> !1.
Page 125 of &29
!2.
!3.
+ac'ing rings, gas'ets, %langes, /olts and nuts, etc. s all /e tagged and suita/l2 stac'ed. $etallic gas'ets s all /e e1amined %or pitting or corrosion mar's. T ese de%ects s all /e /roug t to 0)0.Bs attention immediatel2 and necessar2 remedial measures s all /e ta'en /2 contractor to recti%2 suc de%ects. +rotecti&e grease s all /e applied to metallic gas'ets, %langes, /olts and nuts and ot er e;uipment as necessar2 to protect t em %rom corrosion. 8ll non%errous materials suc as &al&es, instruments, piping, instruments &al&es and %ittings s all /e care%ull2 stored and guarded to protect t em %orm damage and t e%t. $ounted (lectrical +arts a. $ounted electrics and accessories s all /e stored in a dr2 and cool co&ered place a%ter c ec'ing all parts. Care s all /e ta'en to pre&ent ingress o% %oreign matter, moisture or rodents, in suc e;uipments. Glass co&ers s all /e protected /2 pasting paper or tape during andling and installation w ic s all /e remo&ed onl2 w en t e e;uipment is /eing prepared %or testing. Ca/les s all /e protected during storage %orm mec anical damage and %rom a/sorption o% moisture at un-protected ends.
!4.
!5. @ods a.
4elding 4elding rods s all /e stored in a ot dr2 place. Suita/le ot cases s all /e pro&ided /2 t e contractor. #uring storage, welding rods o% di%%erent allo2 materials and categories o% wor' s all /e stored separatel2, identi%ied %or proper use. +rotection against weat er a. T e contractor s all pro&ide at is own cost an2 re;uired tarpaulins, sleepers or concrete /loc's %or protecting t e plant and e;uipment against inclement weat er during storage and installation. T e use o% tarpaulins and wood in t e wor'ing areas, particularl2 w ere welding is in progress, s all /e a&oided as %ar as possi/le to minimi6e %ire a6ards. PAINTING 8ll e;uipment, &al&es, piping etc. s all /e painted as per t e speci%ication gi&en in general re;uirements o% painting and as per re;uirement and appro&al o% +urc aser. INSPECTION
Page 126 of &29
!".
:=.,> :=.,>.: :=.,6
:=.,6.:
5or inspection re%er GS !5
Page 127 of &29
:>.) :>.:
PROEECT SCHEDULE < PROGRESS MONITORING T e pro-ect en&isages installation o% 5ire 5ig ting S2stem and )nter-plant +iping %or <35, <35 GC+ and Caster under 0)0. >+ ase 7 ))? at #u/uri. )nstallation o% t e 5ire 5ig ting s2stem and )nter-plant +iping as speci%ied in t e tec nical part o% t e speci%ication, including deli&er2, erection, testing and commissioning, s all /e completed wit in t e o&erall sc edule o% 18 mont s %rom Zero #ate o% t e +ac'age. Zero date and commissioning mentioned a/o&e and as s own in t e sc edule s all /e same as de%ined in t e tec nical and commercial part o% t e speci%ication. T e pro-ect will /e e1ecuted on turn'e2 /asis, e1cluding ci&il engineering wor', w ic s all /e carried out /2 t e +urc aser, /ased on t e load data and ot er rele&ant details to /e %urnis ed /2 t e success%ul tenderer. T e %eed7/ac' data %or utilities and ser&ices s all also /e %urnis ed /2 t e success%ul tenderer wit in 2 mont s %rom 6ero date, %or preparation o% tec nical speci%ications /2 +urc aser : Consultant. +ro-ect Sc edule T e Tenderer s all su/mit t e %ollowing along wit t e o%%er. O/era-- 3ar-chart sche'(-e T e eads to /e co&ered in t e sc edules s all /roadl2 /e as %ollows = <asic engineering and appro&al +lacement o% orders on su/-&endors #etailed design and engineering including suppl2 o% %eed-/ac' data Su/mission o% .oad #ata %or ci&il wor' : e;uipment %oundation $anu%acture and suppl2 o% all e;uipment: piping: ca/les, etc Su/mission and appro&al o% erection drawings and manuals Suppl2 o% (;uipment (rection o% e;uipment, piping, ca/les, etc. Testing, trial runs and integrated commissioning 5
:>.*
:>., :>.),.:
T e ma-or milestones %or t e pro-ect are to /e ig lig ted in t e sc edule. 5 :>.),.* i? ii? The Te!'erer sha-- a-so 1(r! sh the O11-s teG O!-s te or"a! Bat o! chart 1or e7ec(t o! o1 the proFect. T e success%ul tenderer s all a&e to su/mit t e %ollowing= 7 .oad #ata %or ci&il wor' and e;uipment %oundation wit in 2 mont %rom 6ero date %or detailed design and engineering /2 t e +urc aser to complete t e ci&il wor'. T e detailed pro-ect sc edule in ard and edita/le so%t cop2 co&ering %urt er details o% pro-ect acti&ities, s all /e su/mitted wit in 2 mont s %rom 6ero date, %or appro&al and %inalisation /2 t e +urc aser : Consultant.
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iii? :>.= :>.)=.:
T e %ormat o% progress report to /e discussed and %inalised wit in 1 mont %rom 6ero date. T e progress report in appro&ed %ormat s all /e su/mitted e&er2 mont . Pro"ress Mo! tor !" 8n e%%ecti&e s2stem o% progress monitoring is to /e e&ol&ed to ensure timel2 completion o% all pro-ect acti&ities. )n general, progress o% t e %ollowing ma-or acti&ities is to /e reported. +lacement o% orders on su/-&endors %or /oug t out items #etailed design and engineering including su/mission o% drawings and t eir appro&al. $anu%acturing acti&ities at t e wor's o% t e contractors : su/-&endors. #espatc o% e;uipment to site. Site acti&ities including receipt o% material : e;uipment at site, erection, testing and commissioning.
:>.)=.*
8 mont l2 progress report s owing current status o% &arious acti&ities s all /e su/mitted to t e +urc aser and is consultants /2 t e contractor. T e mont l2 progress report s all indicate progress o% acti&ities against targeted dates and targeted ;uantities. @easons %or s ort%alls, i% an2, s all /e clearl2 /roug t out and proposed remedial measures to arrest t e dela2s s all /e indicated /2 t e contractor in t e progress report, w ere&er applica/le. T e contractor s all su/mit a sc edule %or site-e1ecution, one mont /e%ore start o% site acti&ities. 8%ter t e site acti&ities are started, t e contractor s all %urnis in%ormation on site acti&ities &i6= dail2, wee'l2 and mont l2 reports %or receipt o% e;uipment and erection, mont l2 erection plan and progress, etc. T e contractor s all also indicate resource deplo2ment at site, ig lig ts o% critical areas and constraints in t e site progress reports. 3t er in%ormation related to site acti&ities as ma2 /e re;uired /2 t e +urc aser : Consultant, s all also /e su/mitted /2 t e contractor.
:>.)=.,
Page 129 of &29
:>.)=.= +urc aser : Consultant s all also a&e t e rig t to = )n&ite t e contractor %or mont l2 : %ortnig tl2 re&iew meetings
T e
#epute +urc aserBs aut orised representati&es %or ascertaining : e1pediting progress at contractorBs wor's. Per1or#a!ce "(ara!tee
:6.) :6.:
T e Tenderer s all guarantee %or satis%actor2 per%ormance o% t e e;uipment and material %or a period o% 18 mont s %rom t e date o% completion o% erection >in all respects? and 12 mont s %rom t e date o% commissioning o% e;uipment w ic e&er is later. T e Tenderer s all replace:repair wit in se&en da2s o% recei&ing t e notice at is own cost an2 de%ecti&e parts in t e e;uipment o% is own manu%acture or t ose o% is su/-contractors. 8%ter completion o% erection, cold tests and ot trial runs and %ul%illment o% per%ormance o% indi&idual e;uipment and s2stems, t e integrated s2stem per%ormance guarantee tests s all /e conducted /2 t e Contractor to esta/lis t e rated output. T e per%ormance guarantee tests s all /e completed wit in a time sc edule to /e mutuall2 agreed upon /etween t e +urc aser and t e Contractor. #etails o% t e per%ormance tests, test procedures and test sc edules %or t e demonstration o% t e per%ormance guarantee s all /e su/mitted to t e +urc aser and s all /e mutuall2 agreed upon. )n case, t e per%ormance &alues %all /elow accepta/le le&el, t e unit:su/unit:e;uipment s all /e re-ected /2 t e +urc aser and t e Contractor s all /e lia/le at t e option o% t e +urc aser, eit er to replace t e unit:su/-unit:e;uipment or to pa2 compensation in addition to t e li;uidated damage as per t e contract or as ma2 /e agreed upon. 0o positi&e tolerance s all /e permissi/le %or power consumption o% t e +lant * pumps. 0o negati&e tolerance on t e per%ormance o% t e pump is permissi/le. L st o1 'ra2 !"s < 'oc(#e!ts to 3e 1(r! she' a-o!" 2 th the o11er T e Tenderer s all su/mit t e %ollowing drawings: documents along wit t e o%%er= -
:6.*
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Page 130 of &29
1. 2. 3. 4.
.a2out drawing s owing pump ouse and t e pipelines route to &arious consumers : points %or %ire water wit all dimensions and si6es o% t e pipes. General arrangement drawings o% pump ouse s owing tentati&e dispositions o% &arious e;uipment and piping. General arrangement drawings o% pump sets >)ncluding sump pump sets?, ot er e;uipments and &al&es etc. + * ) diagram o% t e s2stem o% t e %ire water s owing all t e consumers, %low rate, pipe diameters, /road parameters o% eac e;uipment, instruments, interloc's, water losses etc. 4rite -up detailing t e control logic in t e entire water s2stem. <road parameters o% &arious pumps, &al&es and ot er e;uipments as speci%ied in t e speci%ication. #etails o% &arious dri&es, instruments, andling * oisting %acilities and &entilation %acilities, etc. Speci%ication and capacit2 o% all e;uipment, pipes, &al&es etc. o%%ered /2 t e Tenderer. Tentati&e <ill o% Auantities co&ering all e;uipments, &al&es, strainers, pipelines, etc. and associated electrics, instrumentation, andling * oisting %acilities etc. .ist o% special tools and tac'les. .ist o% commissioning spares. .ist o% spares %or two 2ears o% normal operation and maintenance wit item wise prices. Catalogues and literatures o% all e;uipments and &al&es. 3t er drawings and documents as listed in ot er c apters. L st o1 'ra2 !"s a!' 'oc(#e!ts to 3e 1(r! she' a1ter p-ace#e!t o1 or'er For Appro/a-
5. ". 7. 8. 9. 1!. 11. 12. 13. 14. :@.) :@.: 1. 2.
#esign calculations in respect o% si6ing o% storage units, networ' /alancing. 8ll e;uipment and piping si6ing calculations.
Page 131 of &29
3.
.a2out o% eac unit li'e pump ouse, static water tan', pipe networ's, +iping drawings indicating pipe routing, location o% supports, &al&es and ot er %ittings as re;uired. General arrangement drawings o% pump ouses and static water tan' >including ci&il, structural and ot er %acilities? s owing dispositions o% &arious e;uipment and piping. +rocess * instrumentation diagrams %or t e water s2stems indicating location o% all instruments, alarms and interloc's %unctions using )S8 s2m/ols. #rawings:data %or appro&al >4it in %our wee's a%ter placement o% order? +redicted C aracteristic Cur&es s owing ead, s a%t power re;uirement, e%%icienc2 and 0+S9 re;uirement against capacit2. General arrangement drawing s owing o&erall dimensions, weig t including t at o% /ase plate. Sectional drawing s owing material o% construction %or &arious components indicating grades and standards.. G.8. drawing %or t e common /ase plate.
4. 5. ".
7. 8.
#iesel engine G8 drawings. $otor #ata S eet $otor G8 drawings wit all dimensions. 8ll c aracteristic cur&es o% motor including speed tor;ue cur&e o% t e motor Terminal /o1 G8 drg. wit details o% ca/le si6e suita/le %or 8KK t2pe ca/le termination.
9. 1!. 11. 12. 13.
.ist o% instruments comprising /ill o% materials and instrumentation data s eets. #ata s eets and tec nical details o% all t e e;uipments, &al&es and piping. .ist o% sa%et2 interloc's. G8 drawings o% material andling e;uipments. Ca/le la2out drawings and ca/le sc edule.
Page 132 of &29
14. 15. 1". 17. 18. :@.*
Aualit2 8ssurance +lan. Test procedures %or preliminar2 and %inal acceptance tests. 3t er drawings as listed in &arious c apters. @e%er &arious c apters li'e electrical, instrumentation, ci&il, material andling, etc %or ot er drawings to /e su/mitted. 8n2 ot er drawing: documents as re;uired /2 t e +urc aser. Fee' 3ac8 'ataG'ra2 !"s 4+ th ! 1o(r to s 7 2ee8s a1ter p-ace#e!t o1 or'er5
1. 2. 3. :@.,
5irm re;uirement o% cooling and sealing water wit ma1. and min. pressure along wit pipe connection si6e. #imension and weig t o% largest component and ot er in%ormation regarding oisting and andling re;uired %or maintenance. @e%er &arious c apters li'e electrical, instrumentation, ci&il, material andling, etc %or ot er drawings to /e su/mitted. FOR REFERENCE AND RECORD T e success%ul Tenderer s all su/mit re;uired sets o% all t e appro&ed drawings, documents and manuals %or +urc aserBs record and use. 8%ter erection o% e;uipment, t e Tenderer s all su/mit one set o% linen tracings: reproduci/les in re;uired num/er o% prints along wit so%t copies in C# >in 8utoC8# %ormat? o% eac C8s /uilt drawingsD.
1. 2. 3. 4. 5.
+art nos. and description o% spare parts.>wit in eig t to ten wee's a%ter placement o% order? 3perating and maintenance manual %or t e total s2stem. @ecommended Spare parts list and price. )nstruction %or erection and commissioning. $anu%acturerBs test certi%icates.
Page 133 of &29
". 7. 8. 9. 1!. 11. 12. 13. 14. 15. 1". 19.
.u/rication sc edule and ;uantit2 and ;ualit2 o% lu/ricant %or one 2earBs normal normal operation. Earious e;uipment assem/l2 drawings and /ill o% material. 4eld procedure. 92draulic test logs. (;uipment G8 drawings and /ill o% materials. C aracteristics cur&es o% t e pumps, motors and ot er e;uipments. 3peration and maintenance manuals %or all e;uipments, &al&es and complete water s2stem along wit so%t copies. Test and cali/ration certi%icates. 4arrant2: guarantee certi%icates. Tec nical literature, catalogues and manu%acturerBs drawings %or all /roug t out e;uipment, &al&es and ot er items. @e%er &arious c apters li'e electrical, instrumentation, ci&il, material andling, etc %or ot er drawings to /e su/mitted. Test certi%icates %or t e %ollowing= a? /? c? $aterial test certi%icate %or all ma-or e;uipment and t eir components. 92draulic test o% e;uipment, pipe %ittings * &al&es. Static and d2namic /alancing o% all rotar2 parts: e;uipments L st o1 te!'er 'ra2 !"s e!c-ose' T e %ollowing drawings are part o% t e tec nical speci%ications and s all /e re%erred to /2 t e tenderer w ile preparation o% t e o%%er. S-. No. 1. Dra2 !" No. $(C:A"93:11:4!:!87:TS:1!! Re/. No. ! Descr pt o! 3&erall la2out plan %or 5ire water interplant 8! S Be
:A.)
Page 134 of &29
2.
$(C:A"93:11:4!:!87:TS:1!1
pipelines. #etail-N8B
8!
Page 135 of &29

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NEELACHAL ISPAT NIGAM LIMITED DUBURI, ORISSA TECHNICAL SPECIFICATION OF FIRE FIGHTING FACILITIES FOR NINL PHASE -II

PREPARED B$ Cha!'resh G(pta ADE

CHEC%ED B$ L. Mahto Sr. Ma!a"er

APPRO&ED B$ P.S. Rao DGM

TS for Fire Fighting Facilities !ac"age No. 0#$%

01.0 !1.1 !1.2

2009.MECON Limited. All rights reserved

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

!1.1" !1.17 !1.17.1 !1.18 !1.18.1

!1.19 !1.19.1 !1.2! !1.2!.1

2009.MECON Limited. All rights reserved

!1.25.2 !1.25.3 !1.2" !1.2".1

2009.MECON Limited. All rights reserved

!1.29 !1.29.1 !1.29.2

eads- mec anical,

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

!1.29.4 !1.29.5 !1.3!

3t er documents as re%erred in t e &arious c apters o% t e speci%ication.

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

35! 7 45! 1 5 1 1 !.5

++$ >$a1? ++$ ++$ ++$ ++$ ++$

TS for Fire Fighting Facilities !ac"age No. 0#$%

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

!5.! !5.1 !5.!1.1

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

2009.MECON Limited. All rights reserved

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iii? i&? &? &i? &ii?

)6.) )6.: !".!1.1

2009.MECON Limited. All rights reserved

!".!1.11 !".!1.12 !".!1.13

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

P pe D a#eter Lpto #0 15! mm #0 2!! mm to 45! mm !".!1.14 !".!1.15

S(ct o! s 'e !." to 1.! m:s !.8 to 1.2 m:s

De- /er0 s 'e !.9 to 1.5 m:s 1.2 to 1.5 m:s

!".!1.17 !".!1.18 !".!1.19

2009.MECON Limited. All rights reserved

!12. !13. !14.

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

!23. !24. !25. !2".

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

2009.MECON Limited. All rights reserved

TS for Fire Fighting Facilities !ac"age No. 0#$%

2009.MECON Limited. All rights reserved

&ert ca- p(#ps 4 1or 'ra !a"e s0ste# 5.